Metalworking Fluids

Why are metalworking fluids(coolants) necessary?
The metalworking process creates much heat and friction. If the heat and friction are not reduced, the tools used in the process are quickly damaged and/or destroyed. Also, the quality of the products made is diminished because of inefficient tools or damage to the product while it is being manufactured. Coolants reduce friction at the tool/substrate interface and transfer heat away from the tool and material being processed, reducing the time to process the metal, increasing the quality of the workmanship, and increasing tool life. The ability to transfer the heat away from the metal working process is why metal working fluids are often called coolants.

Why do coolants work?
Oils are natural lubricants and provide this quality to coolants that are petroleum-based. Other coolants’ ability to reduce friction comes from lubricating additives. During the metal working process, heat diffuses into the coolant. The “heated” coolant flows off the work area into a collection container or sump, where it cools off and then enters the cycle again. Water has excellent cooling characteristics and many coolants contain water or are primarily water-based to cool the machine process. Soluble oils and semi synthetic oils have both water and oil components. Coolants containing both oil and water require surfactants to form and maintain emulsions, a mixture of the oil and water, so that both properties can work together.

Consideration for choosing a coolant
Different metal working processes have varying cooling and lubrication needs. Coolants have many properties that increase their efficiency, extend their life, and minimize the potential to damage tools and products. Therefore, when choosing a coolant, many factors need to be considered. These considerations include:
  • Tramp oil rejection
  • Ability to settle out solids
  • Bacteria resistance
  • Corrosion and rust resistance
  • Emulsification capability
  • Foaming nature and resistance
  • Optimal coolant life
  • Longevity of coolant as measured against current industrial standards
  • Cost of coolant
  • Chemical restriction and reactivity of coolant
  • Capacity of recycled coolant to prevent galvanic attack
  • Water compatibility requirements: pH, deionized water requirements, mineral content and hardness
  • History of dermatitis.

Coolant effectiveness
The effectiveness of a coolant for heat transfer and as a lubricant decreases for a number of reasons. Coolant break down in process. They accumulate foreign substances including tramp oil, swarf, dissolved minerals, and/or dirt from the process. These substances prevent the coolant from working. Selective depletion of a fluid component could also reduce coolant effectiveness. For example, swarf is particulate metal created during the grinding or cutting of metals. The presence of swarf creates friction, defeating both the lubricating ability and cooling capabilities of the coolant. The increased concentration of tramp oil similarly interferes.

Water requirements
Some coolant manufacturers state that their coolant can use any type of water while others specify deionized water or mineral free water. Deionized water does not contain minerals that in time may interfere with the coolant’s efficiency. Tap water has mineral and ions in it as well as bacteria. Water based coolants will evaporate while sitting in the sump and vaporize while the coolant is being applied to metal working process.
The mineral present are not evaporated and accumulate in the sump increasing the concentration of minerals in the coolant. If tap water is continually used, the mineral content of the coolant continue to increase. Concentrated minerals can form deposits and soaps, gumming up the metal working process. Tap water may be acceptable for the initial preparation of the coolant, (after Technofluids’ REDOX bacteria treatment) but any additional water should be mineral free(deionized or reverse osmosis processed).

Liquid-Liquid Separation

WaterWall® - Complete separation of non-miscible liquids at high flow rate.

Solid-Liquid Separation

Techno-Floc®: Purification process of polar liquid wastes containing colloidal dispersion of solvated particles.

Waste Heat Recovery

TTVM/G® (Torini Thermo-Volumetric Motor/Generator): A waste heat recovery type generator which offers the ability to convert waste heat into electric energy. 
» Go to TTVM/G Website