How to Choose the Right Cutting Oil?

Introduction Metalworking fluids play a vital role in manufacturing processes, where component quality, efficiency, and tool performance are of prime importance. Their functions are to provide lubrication for overcoming friction, dissipate the heat generated and remove chips produced during metal cutting. Selecting the right cutting oil is critical in obtaining the best machining performance.
Since neat and water miscible products offer different attributes, we have specific applications where each is more suitable. Neat cutting oils provide better lubricity whereas, water miscible cutting oils provide better cooling during machining

Applications for Neat Cutting Oils

1. Neat oils are more suited for heavy duty machining applications where the Material Removal Rate (MRR) is high as we have to counter more friction for example, gear hobbing, broaching etc.
2. Due to high lubrication property, these products are able to give better surface finish in critical finishing applications like lapping, honing and even in some critical grinding applications like gear profile grinding.
3. In some cases the machine tank, pump & filtration systems are designed for neat oils and hence, they are preferably used
4. Some materials may react in presence of water making it preferable to use neat oils, example Magnesium

Applications for Water Soluble Cutting Oils

1. Water miscible oils offer better heat dissipation for applications where the machining speeds are high but material removal rate is not too high for example turning, reaming etc.
2. These products also offer better flushing of chips which makes them more suited to application where efficient chip removal is necessary like general grinding
3. Machine, filtration & tank design also leads to selection of water miscible products in some cases.

Zeroing down to the right product is done differently for neat & water soluble oils

Neat Cutting Oil Selection

Primary Selection Factors:

Application severity: The material removal rate drives the need for lubrication. Products with higher viscosity are able to provide better lubrication in more severe applications. Selecting a higher viscosity product in a less severe application may hamper the heat dissipation and the chip flushing.

Material Type: Hard to cut metals resist metal removal by higher friction and hence, require high-lubricity oils, while softer materials may only need effective cooling. Some non-ferrous metals like Copper & its alloys and sensitive grades of Aluminium require products with inactive sulphur-based additives

Machine Tool used: Type of machine tools, their filtration system, presence of chiller, mist collection systems and machining parameters used can also influence selection of the product

Surface Finish Requirements: Accuracy parts post final machining operations may require fluids that assist in a smooth surface finish.

Health, Safety, Environmental Impact: Chlorinated products are toxic and may be carcinogenic over long term usage. Products with base oils derived from plant sources are biodegradable and skin friendly

Water Soluble Cutting Oil Selection

Primary Selection Factors:

Material Type: Ferrous metals have a need more alkalinity to prevent rusting whereas non-ferrous metals may corrode to give stains on the surface. Porous, short chipping metals like cast iron require low oil content to ensure better chip flushing and optimised consumption. Non-ferrous metals like Aluminium alloys are sticky and require higher more lubricity by virtue of additives or oil content. Sensitive non-ferrous alloys require a product with specific dosages of metal de-activators.

Application severity: The material removal rate drives the need for lubrication. Products with higher oil content or lubricity additives are able to provide better lubrication in more difficult applications while grinding requires products with low or no oil content

Machine Tool used: Type of machine tools, their filtration system and coolant pressure used can also influence selection of the product

Health, Safety, Environmental Impact : Chlorinated products, products with boron salts and formaldehyde releasing biocides are toxic and may even be carcinogenic over long term usage.

X-Series high-performance metalworking fluids by Zavenir Daubert are designed to meet to new-age requirements of manufacturing operations.

X-COOL range of water miscible cutting fluids form fine Nano-Emulsion which significantly reduce the carry over losses and these products are formulated selected advanced additive technology which offer the following benefits :

• Low top-up consumption
• High emulsion stability
• Superior corrosion protection
• Cleaner machines & components and
• Long sump life due to high biostability

X-CUT neat cutting oils are formulated using highly refined base oils with high flash points and selected dosages of high-performance Extreme Pressure additives which result in :

• Low evaporation & misting
• Improved tool performance
• Reduced inventory costs due to versatile products
• Superior surface finish & dimensional accuracy