The hottest metal processing fluid management help

2022-08-09
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Metal processing fluid management helps enterprises "reduce costs and increase efficiency"

high quality metal processing fluid can better help processing. How to extend the design cycle of metal processing fluid by referring to ISO 20482:2003 Eriksson cup experiment of metal materials sheet and strip, so as to achieve the purpose of reducing enterprise costs, has attracted the attention of more and more enterprises

choose the appropriate metal working fluid

the emulsion in general metal working fluid is suitable for medium to heavy load cutting and grinding, semi synthetic cutting fluid is suitable for most light to medium load cutting and all types of grinding, and fully synthetic cutting fluid is only suitable for light load cutting and light to medium grinding

1. From the analysis of machining methods, in rough machining with high cutting speed (such as turning, milling and drilling), cutting fluid is required to have good cooling performance. At this time, a smart shoe should choose semi synthetic cutting fluid and low concentration emulsion

in some precision high-strength machining (such as broaching, tapping, deep hole drilling and gear machining), cutting fluid with excellent lubrication performance is required, and high extreme pressure emulsion can be selected

2. From the analysis of using tools

(1) tool steel tools: the heat-resistant temperature of this kind of tools is 200 ~ 300 ℃, the heat-resistant performance is poor, and the hardness will be lost at high temperature. Therefore, it is required to use cutting fluid with good cooling performance, and low concentration emulsion is appropriate

(2) high speed steel cutting tools: during high-speed rough cutting, a large amount of cutting heat is generated. In order to avoid workpiece burns and affect the processing quality, fully synthetic or semi synthetic cutting fluid with good cooling should be used; When using high-speed steel tools for medium and low-speed finishing, in order to reduce the friction between the tool and the workpiece and inhibit the formation of cutting tumors, high concentration emulsion is generally used

(3) cemented carbide tools: these tools have high melting point and hardness, and emulsion can be used in general processing. In case of heavy cutting, the cutting temperature is very high, and it is easy to wear the tool very quickly. At this time, the cooling lubricant with sufficient flow should be used, and the emulsion of 3% - 5% is appropriate (the effect is better if spray cooling is used)

(4) ceramic tools, diamond tools and cubic boron nitride tools: these tools have high hardness and wear resistance. Generally, cutting fluid is not used during cutting. There are high cycle fatigue machines available for metals with large stress, and full synthetic cutting fluid can also be used when it is expressed

the cost of metal working fluid accounts for about 7% - 17% of the total manufacturing cost. Reasonable selection of metal working fluid with high cost performance ratio can reduce the manufacturing cost for enterprises in the first step

cutting fluid maintenance and fluid control

prolong the service life of the processing fluid through good maintenance, so as to reduce the cost. Confirm that the machine tool and water tank are clean before dispensing, then add a certain amount of water into the water tank, slowly add cutting fluid according to the required concentration and fully stir it until the liquid appearance is uniform. Precautions: be sure to mix in a clean water tank; Be sure to pour the oil into the water instead of the opposite; Adjust the concentration with diluent

in actual use, the following parameters will change and need to be controlled:

1 Appearance: the change of appearance is mainly caused by external pollution. Gray or black is mainly caused by sulfate bacteria and saponification of metal particles, which is common in cast iron processing; Brown yellow is related to saponified iron; Creamy substances on the liquid surface indicate that the working fluid is unstable

2. Concentration: the tighter the control, the better, because the operation cost is low when the concentration is 1% - 2% higher than the set concentration

3. PH value: the new liquid is usually between 9.2 ~ 9.5, which will soon drop to 9.0 ~ 9.2 after processing. Daily detection is helpful to prolong the service life of the working liquid, because the decline of pH value is a sign of bacterial infection. If the pH value is lower than 8.7, add bactericide

4. Miscellaneous oil: it mainly comes from the hydraulic and lubrication system of the machine tool, which will promote the growth of bacteria and affect the service life of tools and working fluid. One thing that should be controlled is that the experimental data is displayed on the display screen within 2%, which can be removed by oil skimmer and centrifugation

5. Total hardness: it depends on the total content of calcium and magnesium ions in the water. Too high will affect the stability of the working fluid and the level of foam, resulting in dross and the consumption of fatty acid soap. We can reduce the hardness by adding softened water or reverse osmosis film. Generally, the hardness is controlled at 5 ° DH ~ 30 ° DH

6. Chlorine content: too high will lead to rust and damage the stability of working fluid, which should be controlled within 150ppm, and can be solved by adding softened water and concentrated solution

7. Conductivity: too high will lead to rust and destroy the stability of working fluid, affecting tool life. Should be controlled at 5000 μ Within s/cm, it can be partially replaced and softened water can be added

it can be seen that the service life of metal working fluid mainly depends on the control of external pollution and organic organisms. Practice has proved that good maintenance can double the service life of metal working fluid, and the benefits can be seen. (end)

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