Month: August 2013

Have you fully comprehended metal cutting? Well, this is a complex subject that involves various processes and tools. There are two main metal cutting processes that are very crucial. The first term is metal cutting fluids, while the second term is known as metal cutting technologies. With these two terms, you are well able to understand metal cutting.

Metal cutting fluids

Fluids are majorly used in processing metals for two vital functions. One, they are used for cooling, and secondly, for lubrication during metal working processes. Interconnected to these two functions, the metal cutting fluids are also used to protect metals against corrosion and swarf flushing.

In what form do the metal cutting fluids come?

These fluids may come in the form of liquids, pastes, aerosols and carbon dioxide coolants. The choice for any of the forms will be guided by the type of metal you are processing and the kind of ending that you hope to achieve.

Various environmental and health concerns have been raised about the use of the metal cutting fluids. Use of these fluids for a long time could pose serious health problems if proper safety measures are not applied. This will normally mean that the workers have to use protective clothing while working with the fluids. Proper disposal of the fluids is also vital to ensure that the environment is not degraded.

Metal cutting technologies

The second aspect of metal cutting is that of metal cutting technologies. Various technologies have been used to achieve expected ends. The technologies used in metal cutting will normally depend on the type of metal, its thickness and the quality specification needed by the client in question.

Basically, four major technologies are used which include:

• Oxy fuel,
• plasma,
• laser and
• water jet cutting technologies.

The Oxy fuel metal cutting technologies will normally involve the use of oxygen to form a reaction on the metal that further forms a cut. Plasma technologies involve the use of high temperatures to form an arc that will later cut the metal. Laser cutting will use a well-focused light on a specific part of the metal to cut it. Water jet metal cutting technologies involve the use of pressurized water, which is combined with other abrasives to form a cut on the metal.

Are we safe in using metal working fluids and cutting fluids? This is a concern for a majority of people who normally engage in processing metals. One of the major concerns for the majority of people has been the safety in use of either the metal working fluids or the cutting fluids.

What are metal working fluids?

These are the essential fluids used in cooling and lubricating work pieces during the metal working processes. They are very vital in the reduction of friction and improving the quality of the metal work pieces. They are normally packaged in various forms which include straight oils, liquid oils, synthetic oils and semi synthetic fluids. The choice of any of these will depend on the type of metal that one is processing. It also depends on the quality that you would wish to achieve in the long run.

Cutting fluids are very similar to metal working fluids in that the functions are interrelated. They are normally used as coolants and lubricants during the metal working processes. Cutting fluids are further divided into liquids, gases, gels, and pastes. The choice of each of these fluids will depend on the type of metal and the stage of metal processing that you are engaged in.

What are the safety concerns?

Various people working in industries have overly complained of various health complications. These include respiratory problems, skin irritations and sometimes cancers in the long run. The chips and dust that may come from the metal processing will majorly be the cause of respiratory problems.

Exposure to soluble metal working fluids will bring about skin irritation and allergies. Further, contaminated clothing will lead to skin irritation if no proper measures are applied. Some of the skin conditions experienced include dermatitis and acne among others. Bacterial infections are also likely to appear to a person exposed to the metal working fluids and cutting fluids. Still, lack of proper disposal of the fluids will normally lead to fatal environmental risks. It is therefore important that a person using these fluids wears protective clothing. Further, proper disposal of the products should be done to avoid environmental degradation.

Have you come across the term metal working fluids? Well, here are several key things that will help you understand the term fully. The term is used to describe oils and liquids essential in lubricating and cooling metals during their processing. Furthermore, metal cutting fluids will be used to reduce heat and prevent premature tool wear. The fluids are also essential in ensuring that the quality of the work piece surface finish and are also used to remove chips or swarf.

There are various types of metal working fluids available in the market. The first one is the straight oil which is composed of mineral, animal and vegetable oils. The second type is known as soluble oil that is composed of petroleum oils and emulsifiers. The third type is known as the semi synthetic fluids which combine petroleum oils and water. The last type is known as the synthetic fluids, which are made up of detergent like additives. The choice of either of these fluids will majorly depend on the type of metal being processed and the type of finish one wants to achieve in the long run. A number of additives can be found in each of these types, which include stabilizers, de-foamers, colorants, and dyes among others.

Coolants or cutting oils major functions are cooling and lubricating of the metal and tooling during their processing. Furthermore, cutting oils will be used to prevent rust on the metal piece after the processing. Both the metal cutting fluids and the cutting oils pose various environmental and health concerns if no proper safety measures are applied. Proper disposal and use of protective clothing during their use is therefore very essential.

There are several products available in the markets that are vital for cutting metals. These include metal cutting fluids and cutting oils. The products are developed to meet various needs in processing of metal and their cutting. Firstly, reducing heat and friction in metal processing and cutting is very essential. Metal cutting fluids are essentially formulated to deal with these factors. Further, they aid in removal of particles from the working surfaces while processing metal.

Metal cutting fluids vary from the straight fluids to the water based fluids. Each of the variety is appropriate for different metals and surfaces.  However, most of the fluids will contain several components including pressure additives, corrosion inhibitors, biocides, stabilizers emulsifiers, de-foamers, fragrances, dyes, and colorants among others. Therefore, before you settle on a metal cutting fluid, you must conduct a good research to identify the very appropriate one.

It is of essence to note that storage of metal cutting fluids will bring about contamination from certain formations known as nitrosamines. This will normally occur when the fluids are stored for a long time. Further, several components in the fluids will encourage growth of bacteria that will eventually change the properties of the fluid. Therefore, while purchasing the fluids, consider the length in which the product has stayed on the shelf. Also, purchase the product in small quantities to avoid remainders that will eventually be wasteful.

One of the major concerns is the health implications after using metal cutting fluids. Research has shown that many people are rendered ill after using the products for a long time. This calls for a lot of precaution to avoid health complications such as respiratory illnesses and cancer in the long run.

Cutting fluids are not limited to metal cutting, though their composition and functions are similar to those of metal cutting fluids. They are further used in various machining processes. Various terms are used to refer to the product depending on the context in which they are used. Some of those names include cutting compound, lubricant and coolant among others. They take many other forms including pastes and gels, mists and various gases.

Metal cutting and processing is a complicated activity that involves use of various techniques. The process involves use of a variety of materials. Some of the tools in consideration include metal cutting fluids and cutting oils. The choice of using either of these will majorly depend on the complexity of the task and the costs involved.

Metalworking Fluids

Metal working fluids, normally abbreviated as MWFs, are used to reduce friction and removal of particles after metal processing and other operations. Further, they aid in prevention of burning and smoking of metal work pieces. They are also very useful in improving work pieces by removing chips from the metal surfaces that are being processed.

Metal working fluids are further subdivided into straight, soluble and synthetic oils. The straight oils are also known as neat oils and are normally made of mineral and synthetic oils. Soluble oils contain petroleum oils and other emulsifiers. Synthetic oils contain detergent like additives to bring about wetness in the work pieces. Semi synthetic will normally combine characteristics of straight oils and other additives which are appropriate for some specific work pieces.
Metal working fluids have been associated with several risks in their use. In industries where continuous use is practiced, some workers have been known to develop various health complications. These range from respiratory problems to major illnesses such as cancers. Therefore, a lot of precaution is needed while working with these fluids.

Metal Cutting Oils

Metal cutting oils do not display huge differences compared with metal working fluids as far as the composition is concerned.  However, they differ in functions in which they are used. Cutting oils will normally be used for drilling, milling, tapping and cutting among other functions. Before settling for any specific cutting oil, you must ensure that it has low corrosive tendencies on your work piece. It should also be appropriate for the type of metal that you want to cut. Depending on the composition, the finishing will be different, which calls for a consumer to make excellent choice to achieve expected end.

Metal cutting fluids are specially formulated fluids for metal processing and have various distinct functions. These functions include: helping to ensure that a tool has longer life, minimizing thermal deformation, bringing a finer finish on the working surfaces and eliminating chips from the metal surfaces one is working on.

Metal cutting fluids are further categorized into the following groups

1. Soluble oils
2. Synthetic fluids and
3. Straight oils

The fourth category is a subdivision of the synthetic fluids into semi synthetic fluid. Metal cutting fluids are differentiated depending on the specific materials used to make them. For example, the best oil for lubrication in these categories is the straight oils. These are composed of petroleum oils and polar lubricants.

Synthetic fluids will provide the best cooling services because they contain organic and inorganic products best for that very purpose.  Soluble oils will provide very good lubrication because they are made of minerals oils and emulsifiers. Semi synthetic oils are made of a combination of synthetic and soluble oils and tend to display characteristics of both oils.

It is important to note that metal cutting is a complicated process that requires a lot of time and costs. Various metal cutting technologies are used and may be divided into the following categories:

1. Laser cutting. This involves use of carbon dioxide together with other gases to create a very accurate cut on the metal.
2. Plasma arc cutting technologies. This is where a lot of speed is used to cut the metal using electrically charged gas.
3. Oxy fuel cutting technology. This technology uses various gases to come up with a flame that is then used to cut the metal.
4. Abrasive water jet cutting technology. This technology uses stream water that is highly pressurized to cut metals. Further, an abrasive is introduced to cut more metal materials.

Deciding on which metal cutting technology will depend on the cutting speed, costs involved, the type of metal you need to cut, cleanliness on the edges and access to the material.