training – soluble coolants

ILLUSTRATIONS ARE BASED ON IMAGES AVAILABLE FROM MANUFACTURERS

2021

Training – Soluble coolants

WEBINAR: Machine Shop

About us..Fleissig Solution Pvt Ltd, formed with the vision of serving customers

with high value customised solutions in the domain of Industrial components processing & improving equipment service life by improving productivity, caring of operator’s health, safety our

environment. We offer effective & efficient solutions to deliver optimum

total cost of ownership in every product & services, we cater.

www.fleissig.co.in 2

DIPP42025

Our services

PRODUCTS & EQUIPMENTS

• Performance lubricants & greases• Thin film rust preventives• Metal working fluids• Soluble cleaners• Equipment's for filtration of hydraulic

oils / lubricants • Centrifugal filtration for quenching oils• Tramp oil remover for machine shops• Magnetic filters for better surface finish

on grinding machines

FLUID MANAGEMENT SERVICES

Soluble coolants enhances machining performance when routine care and handling is implemented. These activities can be simple & efficient if executed by dedicated teams. We offer CMS, which involves employing supervisor & fluid handlers as per your requirement to execute activities such as sump cleaning, top-ups, recording of parameters, collection of samples for lab testing & raising alerts to managers on maintenance issues such as leaks, seal failures etc.


BASICS COOLANTSMETAL WORKING FLUIDS

Back to machining


WORKPIECE

CHIP

TOOL

75%

18%

5% 2%

Lubrica

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Cool!

Flush!

Cooling Lubricatio

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Chi

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Types of Cutting Oils


Cooling Lubricatio

nC

hip

Rem

oval Neat Oils Water Soluble Oils

Application Straight (Ready to Use) 3- 10% solution or emulsion

Pros High Lubrication, Low maintenance

High Cooling, Low product consumption

Cons Low Cooling, High Product Consumption

Low Lubrication, High Maintenance

Technology Trends - MWF


Neat Cutting

Water Soluble Cutting

Cleaning

High Viscous Oil

Low Viscous Oil

Synthetic Oil

Mineral Oil Semi Synthetic

Micro Emulsions

HalogenatedSolvents

(TC)

AromaticSolvents (MTO)

Low Salt Aqueous Cleaners

User trends - MWF

HSE Trend• Environment Friendly Products• REACH Compliance• RoHS Compliance• VOC Free• Free of heavy metals & carcinogens

User Trend• Chemical Process Optimizations

• Parts interact with diverse chemistries (solvent, oil or water based).

• High risk of unwanted reactions – damage to process fluids or even parts

• Use of grades having superior corrosion protection

• Humidity & temperature seasonal fluctuations & shop floor environments (dusty or acidic).

• Flash rust - Sudden rejections of parts in bulk

• Dependence on RP oils in process or storage.

• Expert Servicing / Maintenance• Cost & additional process steps


MACRO EMULSION MICRO EMULSION

Formulations – Typical MWF

Mineral MWF Semi-Synthetic MWF


Appearance - Soluble coolants

Milky Soluble Oil

• Light reflected, the emulsion appears milky white

Translucent Soluble Oil

• Light passes through the emulsion & thus appears clear


Water Oil DropletWater

Oil Droplet

MICRO EMULSIONADVANCED SURFACTANT TECHNOLOGY

Advanced MICRO-EMULSION

• High-performance semi-synthetic cutting fluid, specially designed for Light to Heavy duty machining and grinding of CI, steel, SS, AL and Aerospace components

• Balanced pH, suited for soft as well as hard water upto 400 ppm hardness

• Consistent performance, machine cleanliness• Lower top ups, reduced carry over on

component and swarf • Ease of maintenance (no pH/concentration

drop, bacterial growth etc.,)• Improvements in tool life & sump life• Reduced filter paper consumption


CASE STUDY: Spectracut 9110N (Precision machining)

• PROOF OF PERFORMANCE• Implemented the routine SOP to maintain the pH and Concentration,• Removed the tramp oil.& monitored trends in parameters• Analyzed the behavior of the product on machine parts, tool and work piece.• Cleaning properties were improved, machine bed and tools were cleaner as compared to competition.• Tapping Tool life increased by 23% (94Jobs from 76 Jobs)

CHALLENGE

India Industries, Ambattur, Chennai were facing challenges in machining. Material machined were CI, MS & SS. Rusting due to swarf sticking on machine wall and tool post. Tapping tool life needs improvement.Sump Life was <6 months

TRIALS

Machine :TC/VMC ( ACE/AMS)

Tank Size :150-300 L

Product :Spectracut 9110 N

Initial fill . :6-8% (As per the material)

Sump life : >9 Months

Tool Life :Increase by 23%

PRODUCT FEATURES

SpectraCut 9110N is suitable for Cast iron & Steel alloys. It is suitable for high & low pressure machining requirements. It will give good sump life. Good machine cleaning. Excellent tramp oil rejection property

13www.fleissig.co.in

CASE STUDY: Spectracut 9110N (Finish Grinding)

• PROOF OF PERFORMANCE• Machine remains cleaner than earlier • Grinding Dust is clean & dry, where it was sticky with earlier coolant.• Surface finish improved, Range Ra <0.5• No Monday morning smell, foaming• Sump life achieved 12-15 months

CHALLENGE

Greaves Cotton, Pune were interested to improve surface finish in crank shaft grinding. The sump life to be improved to 12 months from 6-9 months. Smell, foaming were very common. Machine cleanliness was challenging due to sticky oil residues & grinding sludge.

TRIALS

Product : Greaves Cotton, Pune

Machine : TOS Grinding Machine

Tank Size : 800 L

Initial fill . : 5%

Sump life : >12 Months

Wheel Life : Excellent

PRODUCT FEATURES

SpectraCut 9110N is suitable for machining & hard part grinding. It is suitable for high & low-pressure machining requirements. It will give good sump life. Good machine cleaning. Excellent tramp oil rejection property


CASE STUDY: Spectracut 9160 (Aluminium machining)

• PROOF OF PERFORMANCE• Implemented the routine SOP to maintain the pH and Concentration,• Sump life improved to 18months from current 3 months• Operators appreciated low maintenance & no smell• Cleaning properties were improved, machine bed and tools were cleaner as compared to competition.• Tapping Tool life in Milling, tapping, Drilling, reaming, drilling is found satisfactory

CHALLENGELeading brand generator manufacturer waslooking to improve below challenges in Cylinderhead machining• Low dimensional Accuracy, tool life, sump life• High Salts containing alloy, would increase

emulsion hardness to 2000 ppm in shortperiod.

• Precision line & very important in overallproduction cycle.

• 24 X 7 X 365 days’ work environment

TRIALS

Machine :VMC

Tank Size :300 L

Product :Spectracut 9160

Initial fill . :6-7%

Sump life : 18 Months


PRODUCT FEATURES

SpectraCut 9160 is suitable for Aluminium Alloys, most Ferrous Alloys, Oil resistant Plastics & other non metalicmaterials. SpectraCut 9160 works better in typical 50 to 400 ppm (calcium carbonate), is suitable for high & low pressure CNC systems & designed for low foam.


CASE STUDY: SpectraCut AS (Aero comp machining)

• PROOF OF PERFORMANCE• Implemented the routine SOP to maintain the pH and Concentration,• Removed the tramp oil.& monitored trends in parameters• Sump life achieved is beyond 1 year & no smell noticed• Cleaning properties improved, machine bed and tools are cleaner as compared to competition.• Tapping Tool life increased by 19%

CHALLENGELeading aero component manufacturer for ISRO &HAL, was interested to improve dimensionalAccuracy, tool life, MWF Bio stability (as Batchproduction) Material compatibility, staining & smellissue with existing supplier. Material machined areAluminum 2000, 7000 & 6061

Aerospace sector surface integrity is of paramountimportance because there is a possibility of fatiguefailure due to residual stresses & crackpropagation, which gets induced due to EPadditives containing Cl, S, P.

TRIALS

Machine :DMG 103V (Deckel Maho)

Tank Size :500 L

Product :Spectracut AS

Initial fill . :6-8%

Sump life : 12+ Months


PRODUCT FEATURES

SpectraCut AS versatile MWF having synthetic lubricity enhancers suitable for Aerospace aluminium & Exotic alloys.

It is free from Boron, Chlorine, Sulphur, Formaldehyde Release Additives, Easily disposable, Non Staining on all Metals.


CARE & HANDLINGSOLUBLE METAL WORKING FLUIDS

Best Practices – Soluble coolants• Daily monitoring of Concentration and pH• Ensure concentration and pH is maintained in the required band throughout• Continuous removal of tramp oil with oil skimmer• Arrest oil leakages• Proper mixing of emulsion while topping up. Use of automatic mixers are always

better.• Use of top up calculator for mixing the right ratio of oil and water• Ensure coolant tank is closed and protected from atmosphere dust and other

external contamination.• Frequent removal of chips accumulated in the machine sump.• Daily data monitoring and recording for ready reference.• Physical Machine checking on daily basis for any other issues.


Benefits of monitoring coolants• Long sump life• Problem free operation• Reduced production loss• Healthy surroundings• Confident customers• Good control of costs• Excellent record keeping


Concentration Control through water addition alone

Time

Concentration Control through water and product addition

Coolant monitoring scope• Regular visits to customers by service associate• Measurement of data daily and recording in online chart• Advising customer on top up volume• Maintaining records at multiple places• Highlighting to maintenance spoc, if any major deviation in parameters• Carrying essential instruments like refractometer, ph meter, TDS meter, Chloride

tests, Bactaslydes etc.• Handling tank side additives like water hardeners, anti-foam….if necessary.• Identifying new areas of improvement in the shop floor


Sump change preparation for soluble MWF’s


Put system cleaner (3%) and biocide (1% ) in the running MWF before removing it from the sump.

Let the machining continue for 24 to 48 hours. The MWF may tend to foam a little, because of the System Cleaner.

Drain the used emulsion completely with sump sucker

Clean the entire sump including machine, thoroughly.§ Physical cleaning by scrapping the sump.§ Clean the tray mesh, magnetic separator, filter

& chip conveyor

Prepare a weak emulsion (2% concentration) & run for 2 hours

Drain the weak emulsion completely & charge fresh emulsion

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2

3

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• Machine cleaning Procedure


Trouble Shooting Guide - MWFObservation

Corrosion L L H

Smell L L H

Poor surface finish

L

Skin irritation H H H

Foam H L L L

Causes

Contamination § Tramp oil§ Alkaline ingress§ Solvents/Degreasers

Concentration § High: Above recommended dilution§ Low: Below recommended dilution

Water Hardness § High: >200ppm§ Ideal: 80-150ppm§ Low: <50ppm

Chlorides<50ppm

pH § High: >9.5§ Ideal: 9.0§ Low: <8.3

Bacteria level § High:10§ Low: 10

System Design

Corrective Action

§ Investigate potential leaks§ Remove tramp oil§ Eliminate source of contamination

§ Correct concentration to recommended dilution

§ High: Increase concentration or change coolant

§ Low: Consider water treatment

§ High: Change coolant and investigate alkaline contamination

§ Low: Increase concentration. Consult your Mobil distributor

§ Change fluid§ Check concentration history§ Consult your Mobil distributor

§ Consider change to machine tool parameters

Startup Checkpoints – Hydraulic Oil• Drain water from drain plugs• Circulate oil in low load, bypassing critical components• Preheating of system with lamp or other sources to be done• Priming of lines / pumps an others components if possible• Open the discharge line and operate the pump in local to ensure air release• Clean/Replace filters• Check for the blockings / scaling and remove that, or hot water circulation with

some soap/ surf will help• Ensure the oil level before startup and also after 10-15 min. system running• Cover the power packs to ensure no dust or foreign material entry


High value services

Pure Performance

Lower CPC

training – soluble coolants

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