Metalworking coolants are an essential piece of the metal manufacturing process. They help to reduce heat, lubricate cutting tools, and extend the life of machinery. However, with so many different types of coolants available, it can be challenging to choose the right one for your specific metalworking application. In this blog post, we will guide you on how to choose the right metalworking coolant for your manufacturing needs.
Key Benefits of Metalworking Coolants
Metalworking coolants are essential in reducing the heat generated during common metalworking processes such as cutting, drilling, and grinding. If the heat generated is not controlled, it can cause damage to the workpiece, tool, and machinery. Metalworking coolants help to reduce heat in the following ways:
1. Absorbing Heat
Metalworking coolants are designed to absorb heat generated during metalworking processes. The coolant flows through the workpiece, absorbing heat as it goes. As the coolant absorbs heat, it gets warmer and eventually reaches its boiling point. The coolant then evaporates, taking the heat with it. This process helps to reduce the heat generated during the metalworking process.
2. Lubricating
Metalworking coolants also act as lubricants during the metalworking process. They help to reduce friction between the workpiece and the tool. Friction generates heat, and if it is not controlled, it can cause damage to the workpiece and tool. By reducing friction, metalworking coolants help to reduce heat and extend the life of the tool and machinery.
3. Cooling
Metalworking coolants are also designed to cool the tool and workpiece during the metalworking process. When the coolant comes into contact with the tool and workpiece, it transfers heat away, reducing the temperature of the workpiece and tool. This helps to prevent damage to the workpiece and tool due to excessive heat.
By reducing heat, metalworking coolants help to extend the life of the tool and machinery, prevent damage to the workpiece, and improve productivity.
Choosing a Metalworking Coolant
Choosing the right metalworking coolant for metal manufacturing requires careful consideration of the type of metal, the operation type, environmental and health factors, cost, and performance. By taking these factors into account, you can choose a coolant that will help you to improve productivity, reduce downtime, and extend the life of your machinery.
Consider the Metal Type
The first thing you need to consider when choosing a coolant is the type of metal you will be working on. Different metals have different properties, and therefore, require different types of coolants. For instance, aluminum, magnesium, and copper are known to have excellent thermal conductivity, and as such, they require coolants with good thermal properties. On the other hand, stainless steel, cast iron, and high carbon steels require coolants with high lubricity properties.
Determine the Operation Type
The type of operation you are performing also plays a significant role in choosing the right coolant. If you are milling or drilling, you need a coolant that has high lubricity to prevent the tool from breaking or chipping. However, if you are grinding, you need a coolant that has good flushing properties to remove chips from the workpiece. Some of the most common operations for using a metalworking coolant include:
1. Turning
Turning is a metalworking process that involves cutting a rotating workpiece with a cutting tool. Metalworking coolants are used during turning to lubricate the cutting tool and workpiece, reduce heat, and improve surface finish.
2. Milling
Milling is a metalworking process that involves cutting a workpiece with a rotating cutter. Metalworking coolants are used during milling to lubricate the cutter and workpiece, reduce heat, and improve surface finish.
3. Drilling
Drilling is a metalworking process that involves cutting a hole in a workpiece using a drill bit. Metalworking coolants are used during drilling to lubricate the drill bit and workpiece, reduce heat, and improve the quality of the hole.
4. Grinding
Grinding is a metalworking process that involves using a grinding wheel to remove material from a workpiece. Metalworking coolants are used during grinding to reduce heat, flush away debris, and improve the surface finish.
5. Boring
Boring is a metalworking process that involves enlarging an existing hole in a workpiece using a boring bar. Metalworking coolants are used during boring to lubricate the boring bar and workpiece, reduce heat, and improve surface finish.
Consider Environmental and Health Factors
When choosing a metalworking coolant, you must consider the impact it will have on the environment and your health. Some coolants contain chemicals that can be harmful to both humans and the environment. Therefore, it is essential to choose a coolant that is environmentally friendly and non-toxic.
Metalworking coolants can be harmful due to their chemical composition, potential for bacterial growth, and the mist or aerosol that can be created during use. Some of the potential harmful effects of metalworking coolants include:
1. Skin irritation and allergies
Direct contact with metalworking coolants can cause skin irritation and allergies. This can occur when the coolant comes into contact with the skin, leading to redness, itching, and even dermatitis.
2. Respiratory problems
The mist or aerosol created during metalworking coolant use can be harmful if inhaled. Prolonged exposure to the mist can lead to respiratory problems such as coughing, wheezing, and shortness of breath.
3. Bacterial growth
Metalworking coolants can provide a suitable environment for bacterial growth if not properly maintained. Bacteria can cause infections, skin irritation, and respiratory problems.
4. Environmental impact
Improper disposal of metalworking coolants can lead to environmental pollution. The chemicals in the coolant can contaminate water sources and harm aquatic life.
It is essential to follow proper safety precautions when using metalworking coolants, including using protective gear, maintaining coolant cleanliness, and disposing of coolant properly. Employers must also provide adequate training and education to workers on the safe use and handling of metalworking coolants.
Evaluate the Cost
The cost of the coolant is also a critical factor to consider when making your decision. Different types of coolants come at different prices, and you must choose one that fits your budget. However, it is important to remember that the cheapest option may not always be the best.
Test and Evaluate Performance
Once you have chosen a coolant, it is essential to test and evaluate its performance. This will help you to determine if it is the right fit for your application. Conducting tests such as pH level, rust protection, and bacterial growth can help you to evaluate the performance of the coolant.
Conclusion
Metalworking coolants are used in various metal manufacturing processes such as turning, milling, drilling, grinding, and boring. The coolants help to reduce heat, lubricate cutting tools, and extend the life of machinery. The specific coolant and application depend on the type of metal and the operation being performed. Fusion proudly provides environmentally-friendly machining coolants in the industry. Shop our products online now or contact us to discuss your specific needs.
