FAQs
The issue of odor that occurs when using cutting fluid.
Cutting fluids are divided into emulsified oils (emulsions), semi-synthetic (microemulsions), and fully synthetic. Emulsified oils contain a large amount of mineral oil, which provides a breeding ground for bacteria, fungi, and mold. Without the addition of biocides, bacteria can proliferate rapidly, leading to foul odors, and using inappropriate biocides may not solve the problem. Currently, biocides are classified into triazine types (BK), morpholine derivatives (MBM), sodium pyrithione, benzisothiazolinone, and phenolic compounds, with BK and MBM being the most commonly used. BK formaldehyde-releasing type is effective against bacteria, while its effect on fungi and mold is average; it is suitable for use in semi-synthetic and fully synthetic fluids, but can cause precipitation and stratification in emulsified oils. Additionally, if there are no bacteria in the machine tool liquid tank, formaldehyde will not be produced, and thus it will not have a sterilizing effect. MBM morpholine types are effective against bacteria, fungi, and mold, making them suitable for use in cutting fluids with high oil content, such as emulsified oils.
Reasons for excessive foaming when using cutting fluid.
The components of cutting fluids contain many surfactants, commonly known as detergents, such as TX-4, Pingpingjia, 6501, 6503, etc. These detergents produce a large amount of foam during use, which is detrimental to machining. It can contaminate the processing environment and cause inconvenience to the production personnel. Leakage from the machine tool can also reduce the cleaning ability of the cutting fluid. In this case, adding a small amount of defoamer (silicone oil has a quick effect, while polyether has strong persistence and can suppress foam) can remedy the situation. Additionally, in summer, it is necessary to increase the content of defoamer in the base fluid, which is also related to the liquid level in the machine tool's liquid tank and the sealing of the circulation pump. Appropriately increasing the amount of defoamer can resolve these issues.
Regarding the issue of workpiece surface turning black and moldy during the processing of aluminum parts.
When processing aluminum and aluminum alloys, attention should be paid to the selection of cutting fluids. Due to the relatively active chemical properties of aluminum, it easily reacts with acids and bases, leading to corrosion, rust spots, blackening, and mold. When addressing these issues, the first consideration is that the pH value of the cutting fluid should not be too high, ideally maintained between 8.5 and 9.0. The rust inhibitors selected need to have corrosion inhibition and pH stability properties, and should be those that can form a protective film on the surface of the workpiece, such as phosphoric esters and sodium silicate. It is advisable to minimize the use of inorganic salt rust inhibitors, and the amount of inorganic salts used should also be kept low. After processing, aluminum parts should be cleaned promptly and then coated with rust preventive oil or other agents that can provide rust protection (or passivation).
The "burn" generated during grinding is due to insufficient cooling or insufficient lubrication?
The issues such as blue burn caused during grinding are due to localized high temperatures. Grinding is a high-speed cutting process that generates instantaneous high temperatures at the grinding point. Therefore, burn issues occur frequently in grinding operations. The role of the grinding fluid is to quickly carry away the accumulated heat from the grinding wheel and workpiece, keeping them at a lower temperature level to ensure the dimensional accuracy of the workpiece. Maintaining the grinding wheel and workpiece at a lower temperature level is certainly effective in reducing the temperature in the grinding zone, but this cooling is indirect. A more direct approach is to improve the lubrication conditions in the grinding zone, which is more effective in reducing the instantaneous high temperatures at the friction points. Therefore, if burn issues occur, the main solution is to enhance the lubricity of the grinding fluid.
Regarding the rusting of workpieces caused by fully synthetic cutting fluids in summer.
Fully synthetic cutting fluids do not contain oil, so many manufacturers choose inorganic salts as rust prevention additives, such as sodium nitrite, boric acid, sodium benzoate, sodium gluconate, and sodium carbonate. Sodium molybdate has excellent rust prevention properties, but it is too expensive. The addition of other inorganic salts generally needs to be high to achieve good rust prevention effects. In hot summer weather, with significant evaporation of moisture, combined with operators not adding cutting fluid in a timely manner, the inorganic salts in the liquid tank can reach saturation. This leads to precipitation, which adheres to the surface of the workpiece, resulting in inadequate rust prevention and causing significant cleaning issues later on. Therefore, appropriately reducing the amount of inorganic salts and adding organic rust inhibitors can improve this situation, such as borate esters, amino acid esters, and carboxylic acids, which not only provide good rust prevention but also create a more stable system.
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