Excellent surface finish, longer tool and die life with minimal coolant consumption, cleaner working environment are some of the desired parameters that directly impact cost per component and productivity levels in metal working processes.
With a number of variables affecting the final finish of the component, role of the coolant/lubricating fluid is critical in achieving higher efficiencies and productivity levels. The basic function of a coolant is to reduce friction between tool and work piece as well as to reduce and dissipate heat in the machining area. To this effect, knowledge of the dynamics involved in tool work interface, the resultant frictional, tangential forces, behaviour of the fluid at elevated temperatures and extreme pressures are imperative in formulating the perfect metal working fluid
METAL CUTTING FLUIDS
BECHEM’s Avantin range are the most advanced breed of metal cutting fluids that have set new benchmarks in the industry by achieving maximum performance with minimal consumption.
NEAT CUTTING OILS
BECHEM’s range of neat oils have excellent EP and anti wear properties essential for increased tool life and achieve superior surface finish.
Beruclean range of cleaners by BECHEM developed with advanced formulation provide spotless and speck free components, leaving no residues mandatory for critical machining processes.
MINIMUM QUANTITY LUBRICANTS
BECHEM’s MQL (Minimum Quantity Lubrication) range of advanced lubricants form a continuous film on the tool and metal job interface with the intention of reducing friction and thereby temperature build up.
Benefits for your Application
Excellent surface finish, longer tool life, minimal consumption of coolants, cleaner machines and hazard free working environment are some of the desired parameters that directly affect cost per component and productivity levels in metal working processes. BECHEM’s range help customers achieve their productivity targets and much more,
Long sump life
- Highly stable emulsion
- Low foaming
- Lower bacterial growth resulting in cleaner work environment
- Excellent corrosion protection
- Contains lubricating improves and possesses excellent flushing properties.
Good machining performance
- Excellent surface finish
- Enhanced tool life
- Excellent dirt carrying capacity
Minimal top-up quantity
- Negligible drag out loss
- Machining : Turning, drilling, milling, grinding, sawing, deep drilling and severe grinding operations
- MQL machining – Machining with Minimum Quantity Lubrication
- Severe Machining : Broaching, thread and gear cutting, thread forming
- Grinding of tungsten carbide tools, honing, engraving, mould construction, die manufacturing processes
- Forming operations : Punching, bending, stamping and massive forming applications
- Heavy duty cleaners : Cleaning of components, tools, bins and other parts
BECHEM Avantin range are the most advanced breed of cutting fluids that have set new benchmarks in the industry by achieving maximum performance with minimal consumption. Fortified with advanced additives the BECHEM Avantin range contend harsh external impurities such as hydraulic oil, swarf and grinding dust whilst delivering unmatched performance.
BECHEM’s MQL range of advanced lubricants form a continuous film on the tool and metal job interface with the intention of reducing friction and thereby temperature build up. Berucut and Beruform range of MQL lubricants possess excellent lubricity as well as good flushing properties.
Beruclean range of industrial cleaners provide spotless and speck free components, leaving no residues on the component for further machining processes. The Beruclean range is available in both aqueous and solvent-based biodegradable variations for wide variety of materials.
FREQUENTLY ASKED QUESTIONS
Emulsifiers help in increasing solubility of the cutting oil in water by breaking down the oil into smaller globules and thereby maintaining a stable and uniform emulsion. A stable emulsion provides longer tank life and also ensures lower carry over loss resulting in minimum top ups.
The basic function of a cutting fluid is to provide adequate lubrication to the tool and work piece friction zone as well as remove heat generated by cooling the deformation area. Some additional properties that are desired in the cutting fluid are,
- Ability to rinse away the metal debris from the friction zone
- Provide adequate protection against corrosion to the machine and work piece
- Compatible to machine paint and ensure stain free machines
- Easy to handle and comply to safety and environmental regulations
Intense amount of heat is generated between the grinding wheel and work piece due to friction and cutting process. Uncontrolled heat can lead to structural damage of the work piece and increase in wear rate of the wheel. Fine dust and metal debris are continuously generated and needs to be cleared out from the wheel, work piece interface. The cutting fluid for Grinding process should possess the right amount of lubricity and cooling property to reduce friction and manage temperature rise. Additionally the cutting fluid should also possess the right amount of detergency and flushing property to clear the fine machined debris.
With a higher dosage of lubricity to reduce friction and temperature rise, the coolant should also contain EP additives that can protect the tool by forming a thin layer between the tool and work piece. Additionally, the cutting fluid should possess the right amount of flushing property to clear the machined swarf from the machined area
Ideally, de mineralized (DM) water with neutral pH of 7 and hardness less than 50 ppm is recommended. The chloride level should be less than 25 ppm with no bacterial and fungal presence. Usage of hard water leads to increased conductivity, hence poor rust protection and lower sump life.
‘Oil into water’ or ‘oil in last (OIL)’ is a recommended practice for better solubility of the coolant in water. Water in oil would result in large size oil globules with the oil loving ‘oleopphilic’ ions of the emulsifier being ineffective. This would lead to a unstable oil water emulsion.
- Keep a regular check on the concentration of the emulsion, maintain recommended concentration
- Remove any tramp oil from the coolant tank thoroughly
- Measure pH regularly
- Avoid all sorts of dust near the tank, remove the machined debris from the tank regularly.
- Follow the prescribed procedure while changing the coolant.
Including the effectiveness of ‘cutting fluid’, tool life is impacted by a host of other parameters including cutting speed, feed rate, depth of cut, tool and work material, nature of cut and machine rigidity. Cutting fluids with high amount of EP additives would insulate the tool from frictional wear and ensure longer life. Studies have shown that with all other parameters remaining the same, cutting fluids with good EP properties can increase tool life by 20 to 40%.
Aluminum alloys which contain Copper and Zinc as alloying elements are susceptible to chemical reaction (black stains) with cutting fluids that contain Amines as ingredient. For machining such Aluminum alloys, amine free cutting fluids are recommended
Colour change of the emulsion is notable during machining of Cast Iron with the Fe ions dissolving with the emulsion. However with all other parameters such as pH, conductivity, concentration and microbial behavior remaining within the specified limits, colour change does not impact performance of the emulsion.
Operators handling components with bare hands and in constant touch with the emulsion could feel irritation and itchiness or develop rashes as well. As sensitivity of the skin is subjective, operators need to handle machined components with proper gloves and other protective gear with the objective of avoiding direct contact with the emulsion. Barrier creams could also be considered where direct contact is unavoidable.
Ensuring a stable emulsion with regular check on pH levels and microbial growth by removing chips, swarf and tramp oil from the tank will also help in reducing possibilities of such concerns. Encourage operators to maintain good personal hygiene, recommend regular laundry of their work dress, avoiding wet rags into pockets, usage of mild soaps etc.