Cutting fluid

Thin-wall milling of aluminum using a water-based cutting fluid on the milling cutter.
Cutting fluids are various fluids that are used in machining to cool and lubricate the cutting tool. There
are various kinds of cutting fluids, which include oils, oil-water emulsions, pastes, gels, and mists.
They may be made from petroleum distillates, animal fats, plant oils, or other raw ingredients.
Depending on context and on which type of cutting fluid is being considered, it may be referred to as
cutting fluid, cutting oil, cutting compound, coolant, or lubricant.
Every kind of machining (e.g., turning, boring, drilling, milling, broaching, grinding, sawing, shaping,
planing, reaming, tapping) can potentially benefit from one kind of cutting fluid or another, depending
on workpiece material. (Cast iron and brass are usually machined dry. Interrupted cuts such as milling
with carbide cutters are usually recommended to be used dry due to damage to the cutters caused by
thermoshock.)
The properties that are sought after in a good cutting fluid are the ability to:
• keep the workpiece at a stable temperature (critical when working to close tolerances). Very
warm is OK, but extremely hot or alternating hot-and-cold are avoided.
• maximize the life of the cutting tip by lubricating the working edge and reducing tip
welding.
• ensure safety for the people handling it (toxicity, bacteria, fungi) and for the environment
upon disposal.
• prevent rust on machine parts and cutters.
Lubrication

Lubrication of the ship steam engine crankshaft. The two bottles with lubricant are attached to the
piston and move while the engine is operating
Lubrication is the process, or technique employed to reduce wear of one or both surfaces in close
proximity, and moving relative to each another, by interposing a substance called lubricant between the
surfaces to carry or to help carry the load (pressure generated) between the opposing surfaces. The
interposed lubricant film can be a solid, (eg graphite, MoS2)[1] a solid/liquid dispersion, a liquid, a
liquid-liquid dispersion (greases) or exceptionally a gas.
In the most common case the applied load is carried by pressure generated within the fluid due to the
frictional viscous resistance to motion of the lubricating fluid between the surfaces.
Lubrication can also describe the phenomenon such reduction of wear occurs without human
intervention (aquaplaning on a road).
The science of friction, lubrication and wear is called tribology.
Adequate lubrication allows smooth continuous operation of equipment, with only mild wear, and
without excessive stresses or seizures at bearings. When lubrication breaks down, metal or other
components can rub destructively over each other, causing destructive damage, heat, and failure.

The regimes of lubrication

As the load increases on the contacting surfaces three distinct situations can be observed with respect to
the mode of lubrication, which are called regimes of lubrication:
• Fluid film lubrication is the lubrication regime in which through viscous forces the load is
fully supported by the lubricant within the space or gap between the parts in motion relative to
one another (the lubricated conjunction) and solid-solid contact is avoided.[2]
• Hydrostatic lubrication is when an external pressure is applied to the lubricant in
the bearing, to maintain the fluid lubricant film where it would otherwise be squeezed
out.
• Hydrodynamic lubrication is where the motion of the contacting surfaces, and the
exact design of the bearing is used to pump lubricant around the bearing to maintain the
lubricating film. This design of bearing may wear when started or stopped, as the
lubricant film breaks down.
• Elastohydrodynamic lubrication: The opposing surfaces are separated but there occurs
some interaction between the raised solid features called asperities, and there is an elastic
deformation on the contacting surface enlarging the load bearing area whereby the viscous
resistance of the lubricant becomes capable of supporting the load.
• Boundary lubrication (also called boundary film lubrication): The bodies come into closer
contact at their asperities; the heat developed by the local pressures causes a condition which is
called stick-slip and some asperities break off. At the elevated temperature and pressure
conditions chemically reactive constituents of the lubricant react with the contact surface
forming a highly resistant tenacious layer, or film on the moving solid surfaces (boundary film)
which is capable of supporting the load and major wear or breakdown is avoided. Boundary
lubrication is also defined as that regime in which the load is carried by the surface asperities
rather than by the lubricant.[3]
Beside supporting the load the lubricant may have to perform other functions as well, for instance it
may cool the contact areas and remove wear products. While carrying out these functions the lubricant
is constantly replaced from the contact areas either by the relative movement (hydrodynamics) or by
externally induced forces.
Lubrication is required for correct operation of mechanical systems pistons, pumps, cams, bearings,
turbines, cutting tools etc where without lubrication the pressure between the surfaces in close
proximity would generate enough heat for rapid surface damage which in a coarsened condition may
literally weld the surfaces together, causing seizure.
The importance of lubrication

A report from Dow Corning claims that billions of euros are lost each year because of unnecessary
repair work which has to be carried out on processing equipment that has not been sufficiently
lubricated. The report details a host of measures that food processing companies can take in order to
avoid such expense.
Mechanical wear in food and beverage factories due to surface degradation including mechanical wear
and fatigue - a high percentage of which is due to lubricant degradation and problems associated with
related maintenance. The food industry is especially vulnerable. Given the wet nature of much of the
manufacturing process, the constant need for wash downs, and the dramatic temperature variations
from freezers to ovens, the food industry must pay particular attention to the lubricants they use and the
suppliers they choose to employ, the report says.The wrong lubricant, or the correct lubricant applied in
the wrong manner, can halt plant operations. With so much at stake, making sure that the right lubricant
is used at the right time is critical.
Total lubrication management
To recapture money lost through their own maintenance efforts, the report highlights how many
companies are beginning to turn to outside consultants to implement Total Lubrication Management
programmes. Consolidating lubricant purchases into a single, integrated program can enhance
productivity by making it easier to automate preventive maintenance routines, increase the efficiency of
inventory management, and use a local product supply to reduce on-site inventory costs.
While Total Lubrication Management is a seemingly simple concept, success almost always depends
on finding the right single source of lubrication products and services to meet complex needs.
Complete product line
The suppliers best equipped to meet requirements for diverse lubricating solutions offer a complete line
of industrial lubricants, not just a "wide range" of products. Food-grade lubricants must perform the
same technical functions as any other lubricant such as protection against wear, friction, corrosion and
oxidation, as well as comply with food/health and safety regulations.
Maintenance professionals will also want to ensure the product line includes lubricants suited for
extreme temperatures, especially fluids that will not degrade due to emulsification with water. Fluids
for high-volume applications include hydraulic, compressor and vacuum pump, gearbox and chain, and
multipurpose oils. Specialised industrial compounds such as greases, pastes, anti-friction coatings, and
dispersions must be added to the mix. In addition, a wide range of base stocks is essential. Synthetics
provide excellent resistance to emulsification and last longer to extend maintenance intervals.
Ultra-high purity mineral oils also resist emulsification and promote improved additive performance,
which results in longer life than conventional mineral oils. The full-line supplier must also be able to
draw on functional additive technologies including anti-oxidant, anti-wear, and extreme temperature
additives.
Knowledge of equipment and applications
Effective lubricant consolidation demands technical support from local representatives who know the
right lubricants to use at the right time. Their expertise helps maintenance professionals avoid mistakes
in lubricant selection and application that can shorten equipment life and stop production. For example,
with newer base oil and additive technology, H-1/food grade lubricants perform better than
conventional, non-food grade products at competitive price level.

An experienced Lubrication Manager will be able to determine in which application a food grade
lubricant should be selected and which strategies are basically used to introduce food grade lubricants
in food processing plants and whether you need to switch the entire facility to H1 lubes, just in specific
risk areas or zones within the plant, or on a machine-by-machine basis.
Oil analysis
Integrated oil analysis/monitoring provides important criteria that help determine when oil drain
intervals can be extended, and prevents wasteful early change outs. At the same time, superior-
performing lubricants of the highest quality can pay for themselves in many instances through extended
drain intervals and longer life for plant machinery and equipment. Less product use and less
maintenance time means less cost, the report stresses.
To gauge the condition of industrial lubricants in service, an integrated oil analysis program is essential
to compare each lubricant with its own performance benchmarks. Effective analysis tracks multiple
critical wear-related characteristics of oil in service by comparing the results with previous reports, and
notes the trends. As an essential part of a lubricant consolidation program, oil analysis helps identify
contamination, lubricant degradation, and abnormal machine wear. Industry-accepted tests reveal the
presence of metal particles, water, and other contaminants.
Lubrication management software
The report also highlights how dedicated lubrication management software is a powerful tool to
schedule, supervise, and record a consolidated lubrication programme. It exploits and complements oil
analysis by collecting trend data and developing responsive lubrication schedules. By enabling
maintenance managers and workers to schedule and record lubrication changes for specific equipment,
lubrication software automates the lubrication management function.
A typical large plant, for example, requires maintenance managers to track a complex schedule of
lubricants and applications. While general maintenance software cannot manage complex lubrication
programs, dedicated lubrication management software can help reduce lubrication errors by
automatically generating information that coordinate daily maintenance routines in the most efficient
manner possible. The software also identifies opportunities to more efficiently schedule lubricant
orders and reduce inventory.
Cut cost, extend equipment life
In a complex food manufacturing operation, commodity lubricants bought from many suppliers are
easy to take for granted. This, the report stresses, is a mistake that can compromise productivity and
profitability. The consolidation of lubricant purchasing with the right supplier can help manage and
enhance a key maintenance function. However, the selected vendor must offer a complete solution in
the form of a full line of lubricants and fluids backed by local distribution and technical support.
The package should include detailed oil analysis services and lubrication management software to track
lubricant scheduling. The key difference between a full-service lubricant supplier as a partner rather
than a vendor is the ability of a locally supported total lubrication program that enables maintenance
managers to cut lubricating costs and extend the lives of costly equipment.

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