Cutting oil and coolant developments

Released this month (April 2010) is Master Chemical's TRIM E715, a new variant of its TRIM E708 cutting and grinding fluid concentrate, which, when released, is said to have found favour in Europe's job shops. This was the case because Master Chemical (01449 726800) had, with TRIM 708, formulated a universal coolant whose stable and predictable performance belied its low cost, says the company. TRIM E715 has all the features and attributes of TRIM E708, but contains no formaldehyde donor biocides. Instead, it contains an alternative biocide package to ensure long sump life. This, says the company, is a legislation-driven development, as certain EU countries have placed restrictions on the use of formaldehyde donor biocides in metalworking fluids. Although not a revolutionary introduction, admits Master Chemical, TRIM E715 extends the scope of TRIM E708, which continues to do "an excellent job for a modest price". Both are said to require minimal maintenance, even in the most demanding of fluid management systems, and have the chemical and mechanical lubricity for medium to high duty machining and grinding. Image: Master Chemical's TRIM E715 extends the scope of TRIM E708, which continues to do "an excellent job for a modest price" Like its forerunner, TRIM E715 is hard-water-tolerant and low foaming.This extremely fine soluble oil emulsion is compatible with a wide range of ferrous and non-ferrous metals, with field trials having proved its ability to achieve a particularly good surface finish on aluminium. It has also been formulated to run effectively for long periods, without the need for costly additives. A recent product unveiling from Fuchs Lubricants (01782 203700) has been its titanium-focused ECOCOOL S761. It is approved by Boeing against its specification BAC 5008, the first to meet the new stringent criteria, it is claimed. Tests conducted in the USA and UK demonstrate its benefits, especially as regards tool life in high metal removal rate operations. At one aerospace customer, monthly tool breakages were down from 259 with conventional technology to 83 with ECOCOOL S 761 B. This equated to a monthly tooling cost saving of over £15,000, underlines Fuchs. CARBIDE HOBBING SUPPORT Unveiled by Shell (0161 499 4000) at the recent METAV manufacturing technology show in Germany was a product aimed at gear cutting when using carbide hobs. Shell's Germany metalworking fluids organisation, Shell Macron GmbH, was underscoring Macron 630 S-9: a neat cutting oil that can both withstand the high temperatures that are generated during the process, as well as satisfy leading edge filtration requirements, via its low viscosity. Water soluble cutting fluids are not a sensible proposition for gear cutting with carbide hobs, because of the high temperatures reached at the cutting edge, which can exceed 100 °C. Oil's evaporation point is in excess of 300 °C, it is noted. Additives have also been selected to withstand the high temperatures, such that they do not break down, burn or produce elements that combine with components' surfaces. On the viscosity front, Shell notes that, while it was not previously the case, cutting oil would be filtered in gear hobbing operations, but that now filtration in the range 20 to 50 micron is demanded, which calls for modification to viscosity, if filtering times or surface area are to be kept to the minimum. Macron 630 S-9 offers a viscosity value of 10 mm2/sec at 40 °C . Also part of the Shell offering at METAV was its Shell Macron 400 and 620 tri-purpose cutting oils. Intended for where cross-contamination may be a possibility, Shell Macron 400 and Shell Macron 620 oils are formulated to work as a cutting fluid, gear oil and hydraulic fluid. In other words, where one product does the work of three. Image: Shell Macron, doing the job of cutting fluid, gear oil and hydraulic fluid Shell Macron 400 M-22/32/46 is said to be ideal for multi-spindle or Swiss-type turning lathes, and is recommended for brass, aluminium and light to medium severe steel machining, as well as being free of chlorine and heavy metals. As demonstration of its performance outside of its cutting task, Shell highlights that Shell Macron 400 M-32 outperforms hydraulic and gear oil standards (see graphic, above). Shell Macron 620 M-22/32/46 is the extreme pressure version of Shell Macron 400 series and is recommended for machining a range of steels from medium to high tensile strength, through to stainless steel. It is also free of chlorine and heavy metals. All Macron products are sulphur-free, incidentally. EXTREME PERFORMANCE A new extreme performance soluble range of six metalworking fluids, called the Q8 Baroni X Range, has been launched by Q8Oils (0113 235 0555). Q8 Baroni XMP is a multipurpose, long life, semi-synthetic, water-soluble cutting and grinding fluid, offering high performance and increased tool life on difficult machining applications, plus very low foam characteristics. Q8 Baroni XSP is a multipurpose, long-life, semi-synthetic, water-soluble cutting and grinding fluid, giving high performance on difficult-to-machine alloys.Q8 Baroni XAA is a high oil content, water-soluble cutting fluid that works well in extreme hard water areas, offering improved lubricity over conventional products. Q8 Baroni XLF is a medium oil content, water-soluble cutting fluid, offering high performance levels in both machineability and fluid life, and for all heavy duty applications on difficult-to-machine materials, including Inconels, titanium alloys and aluminium alloys.Q8 Baroni XCI and Q8 Baroni XGP are semi-synthetic, chlorine and sulphur-free water soluble cutting fluids, compatible for ferrous and non-ferrous materials. Traditionally, materials such as cast iron, black bar and flame cut steel can spoil the appearance of cutting fluids and promote premature degradation. Q8 Baroni XCI (soft and hard water) has been developed to address these problems by maintaining fluid and machine cleanliness, as well as reducing drag out over conventional cutting fluids. Q8 Baroni XGP (soft and hard water) is recommended for all machining operations. (See box item, below, for extended test results information). Mobile (European help desk, +420 221 456 426) also unveiled new products late last year, including Mobilgrind, a series of neat cutting and grinding oils for high speed grinding applications where excellent surface finish, high precision machining and improved productivity are the primary objectives. These can be used with conventional and CBN grinding wheels. They have low viscosity, helping to improve machining performance through enhanced penetration at the wheel/component interface and to keep the grinding wheel clean. The lower viscosity also helps to reduce metal fines and particulates in the oil, and to aid filtration and drainage off components, machine and swarf to keep consumption levels as low as possible. Mobile also launched Mobilcut 100, 200 and 300, a series respectively comprising milky emulsions, high performance micro-emulsions and fully synthetic fluids, designed to offer long service life, good operator acceptability and easy waste management. From cast iron and carbon steels to aluminium, from drilling and grinding to reaming and tapping, the Mobilcut products are said to offer multi-functionality and high machining performance in critical machine tools. Box item Q8 Baroni under test Q8Oils' new soluble metalworking fluids, the Q8 Baroni X Range launched last September, were put through extensive testing. These are the reported results. Q8 Baroni XSP, Q8 Baroni XAA and Q8 Baroni XMP were trialled in a range of industrial machining tests, ranging from milling aerospace specification alloys and steel to copper containing alloys. Testing Q8 Baroni XSP "We worked closely with an aerospace component manufacturer in Manchester to give us a good spread of materials and testing conditions," explains Phil Davies, commercial manager at Q8Oils. "The firm produces components for two of the Formula 1 racing teams, as well as aircraft parts. That meant they had the twin pressures of time and accuracy to work under - an ideal testing ground." The firm used Q8 Baroni XSP in three Mazak FH-4000 machine tools and the product was put on a condition monitoring programme, with the machines sampled on a two-weekly basis. "The machines used were 3-axis CNC machining centres, cutting a variety of materials," Mr Davies continues. "We tested Q8 Baroni XSP on low to medium tensile steels, stainless steels and a small amount of copper containing and aerospace specification alloys." The machines' operators were responsible for machine 'top up', with no input from Q8Oils or additions to the sumps of additives. Q8Oils wanted to make sure that the fluid was used under realistic conditions. Concentrations were between 3 and 8 per cent, with the majority of concentrations being in the 4 per cent to 8 per cent region. The operators found the product totally acceptable, in terms of cutting performance, cleanliness and smell. The Q8Oils' test team questioned the operators at each visit and found there were no adverse comments throughout the trial. The team also monitored PH values closely. Mike Phillips, Q8Oils' technical sales manager, explains: "Q8 Baroni XSP maintained a good working pH over the period of the trial, rarely dropping below 8.8. We didn't get a single case of corrosion, bad odour or lack of performance and, even after six months, the fluid stayed in a perfectly useable condition." Testing Q8 Baroni XAA The same aerospace component manufacturer also ran extensive field trials with Q8 Baroni XAA. Again, the fluid was used in the three Mazak FH-4000 machine tools and on cutting low to medium tensile steels, stainless steels and a small amount of copper containing alloys. The new fluids were also tested with several aerospace specification alloys. "The tests found that the cutting performance, cleanliness and smell of Q8 Baroni XAA were all excellent, with no negative comments from any of the operators," reports Mr Phillips. Q8Oils also monitored the pH values of the machines' fluids over the trials and Q8 Baroni XAA demonstrated an excellent ability to maintain a good working pH, rarely dropping below pH 8.6. Again, there were no cases of corrosion, bad odour or lack of performance and, after six months in each machine tool, the fluid was still in a fully useable condition. Testing Q8 Baroni XMP Q8 Baroni XMP was tested at Micromass, a small sub-contractor, based in the north of England, responsible for machine precision components for mass spectrometer manufacturer. Mr Phillips again: "As with Q8 Baroni XAA and Q8 Baroni XSP, the test team placed the new product on a condition monitoring program and sampled each machine on a two-weekly basis." The tests were based on two pedestal milling machines and four CNC machines (two vertical and two horizontal) cutting a variety of materials, including low to medium tensile strength steels, and a small amount of yellow metals and alloys. Phil Davies comments: "The machine operators were responsible for topping up the machines, with no input from Q8Oils or any additives added to the sumps; the idea being that the fluid is used in totally realistic conditions." Once more, the test team monitored pH values closely and found that Q8 Baroni XMP maintained a good working pH over the period of the trial, rarely dropping below 8.6. There were no cases of corrosion, bad odour or lack of performance. In this respect, the fluid was still in a useable condition after six months in each machine tool. Concentrations were between 3 and 8 per cent, with the majority of concentrations being in the more realistic 4 to 6 per cent region. The operators found the product very acceptable, in terms of cutting performance, cleanliness and smell. There were no adverse comments since trial initiation, as key operators were questioned at each visit. Test results in detail Q8 Baroni XSP Metals machined - mainly aluminium alloys, aerospace spec. materials, stainless steel. Machining operations - mainly turning, milling and drilling and taping, including roll tapping. Water Quality – 200 ppm total hardness. Maximum fluid delivery pressure - 30-60 bar. Filtration –some pump protection filtration and some inline product filtration. Mixing System - the emulsion is prepared using a Dosatron positve displacement mixing pump. Other comments - there is some ingress in most machines of the Way lubricant and hydraulic oil, which is removed. pH levels - Q8 Baroni XSP demonstrated good pH control, with a lower limit of 8.8 during the trial period and a typical figure of around 8.9-9.1 was found in each machine Bacteria levels - bacterial control was good throughout the trial, with a maximum bacterial population of 103 colony forming units per ml. in any of the trial machines. Corrosion - no corrosion was exhibited, either on components, tooling or machine bed during the trial. No staining observed on the exotic alloys. Foam control - no foaming was exhibited in any of the machines during the trial. Machining performance - as a heavy duty semi-synthetic, the product performed well. Good surface finish was achieved and component rejection rates were extremely low. Oil content - approximately 45 per cent Emulsion type - semi translucent Emulsion stabilities: Distilled water - translucent emulsion/stable overnight 200 ppm water - translucent emulsion/opaque overnight 500 ppm water - semi translucent/opaque and slight scum overnight PH @ 3 per cent - 9.4 Applications - turning, milling, drilling, threading, boring, deep hole drilling and reaming operations. Creep feed grinding. Metals suitability - primarily designed for use on difficult to machine materials, such as aerospace alloys of aluminium and titanium. Equally suited to ferrous alloys, plastics and polymers. Water compatibility - readily forms a semi translucent, stable emulsion in a wide variety of water qualities. Avoid water with high chloride content (above 50 parts per million) and high calcium or magnesium contents (above 350 parts per million.) Product limitations - care should be taken when recommending for use on sensitive materials; compatibility should be checked for potential to stain. Field Trial Summary – Q8 Baroni XAA Metals machined - mainly aluminium alloys, aerospace spec materials. Machining operations - mainly turning, milling, drilling and taping. Water quality - 350-400 ppm total hardness. Maximum fluid delivery pressure - 30-60 bar Filtration - some pump protection filtration and some inline product filtration. Mixing system - the emulsion is prepared using a Dosatron positve displacement mixing pump. Other comments - there is some ingress in most machines of the way lubricant and hydraulic oil, which is removed. pH levels - Q8 Baroni XAA demonstrated good pH control, with a lower limit of 8.6 during the trial period and a typical figure of around 8.7-8.9 being found in each machine. Bacteria levels - bacterial control was good throughout the trial with a maximum bacterial population of 104 colony forming units per ml. in any of the trial machines. Corrosion - no corrosion was exhibited either on components, tooling or machine bed during the trial. No staining observed on the exotic alloys. Foam control - no foaming was exhibited in any of the machines during the trial. Machining performance - as a heavy duty semi-synthetic, the product performed well. Good surface finish was achieved and component rejection rates were extremely low. Oil content - approximately 60 per cent Emulsion type - milky Emulsion stabilities: Distilled water - semi-translucent emulsion/stable overnight 200 ppm water – milky emulsion/opaque overnight 500 ppm water - milky emulsion/opaque no scum PH @ 3 per cent - 9.1 Applications - sawing, turning, milling, drilling, threading, reaming and most other chip forming processes. General-purpose surface and cylindrical grinding. Metals suitability - suitable for a wide variety of materials, including all ferrous alloys, aerospace aluminium and titanium alloys. Yellow metal alloys. Oil resistant plastic and composite materials. Water compatibility - readily forms a milky, stable emulsion in a wide variety of water qualities. Avoid water with high chloride content (above 50 parts per million) and high calcium or magnesium contents (above 500 parts per million.) Product limitations - care should be taken when recommending for use on very sensitive materials; compatibility should always be checked for potential to stain. First published in Machinery, April 2010