METALWORKING AND PRESERVATIVE FLUIDS
Ultra High Efficiency For All Metalworking Operations

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Steel Shield Metalworking Lubricants Drill & Tap not only protect and lubricate the workshop machines and raw materials (metals), ABF Technology helps to increase cutting speeds and reduce tool head & metal surface temperatures, and Most Important of All works finished with high precision. Unlike conventional lubricants which only lubricate the machines, Steel Shield lubricants treat the metal for enhanced endurance at work. The results are increased productivity, decrease in energy consumption and defective products, and higher quality finished products.


More than half of the lubricants used in metalworking processing are used in metal removal processes. The 4 main functions of metalworking operations are:

  • Metal Removal: Turing, milling, drilling, etc.
  • Metal Forming: Drawing, rolling, stamping, shaping, etc.
  • Metal Protection and Preservation: Corrosion, rust protection
  • Metal Heat Treatment: Quenching, etc

The following 3 main critera are influencing each other, and they need to be considered in metalworking fluid selections:

  • Cutting Fluid
  • Machining Operation
  • Metal Machinability

Types Of Metalworking Fluids

Generally, oil based fluids are used in operations which require optimium lubricity. In constrast, water based fluids are used in the processes where optimium cooling is the first priority.

Main Metalworking Fluid Categories

Additives are added to all the fluids mentioned in the following tables. Additives can be included: emulsifiers, anti-oxidants, anti-foam agents, anti-rust agents, bactericides, extreme pressure additives, etc.

Straight, Mineral Based and Neat Oils
Category Descriptions and Applications
Straight Mineral Oils

The simplest type of metalworking fluid. Usually, they are being used in light duty working of ferrous and non-ferrous metals, and used as a base oil for more complex oils bendings.

Fatty Oils

The product of mineral oils and fatty oil additive (such as palm oil, lard and coconut oil). But they have odours during applications and expensive to blend. They are being used in ferrous and non-ferrous metals metalworkings without stains. They help to achieve high surface finish quality and being used in automatic screw manufacturing machines.

Sulphurized Fatty Oil and Mineral Oil Blend

The product of sulphurized fat and mineral oil which provides outstanding lubricity and stain resistance. These fluids provide extreme pressure protection and extended tool life because their strong chemical bonds do not release until contact temperature of 265℃ are reached. They are being used in ferrous and non-ferrous metals metalworkings without stains. They are the "Inactive" cutting fluid.

Sulphurized Mineral Oils

The product of sulphur additives and mineral oil. They form iron sulphide during machining operations which reduces the tool and workpiece interface frictions, and reduces "built-up" edge created by metal adhesion to the tool. They are being used in ductile metals tough machining. But not suitable for yellow metals (e.g. copper) because of the sulphur reactivity (classified as "Active" Type cutting fluid).

Sulpho-Chlorinated Mineral Oils

A combination of sulphur and chlorine additives which provides outstanding anti-weld abilities over a wide range of temperature. They are commonly being used in threading operations. When fatty oil is added, they whole product can be used in heavy-duty and slow speed cutting processes. But they can mist and smoke during operation which makes them not being used as coolants.

Water Miscible Fluids
Category Descriptions and Applications
Emulsified Soluble Oils

They are concentrates containing an emslsifier (sulphonate in general) which will be mixed with water at ratios within 10:1 to 50:1 to form emulsified particles in 80 to 200 micron. The extreme pressure abilities of the fluid can be enhanced by adding sulphur, chloring or phosphorous additives. In heavy-duty operations, fatty acids or esters can be added to the fatty oils to enhance their abilities. Hard water can break these emulsions and form precipitates. The final cutting fluid emulsion is milky or opaque in colour which consists of 2% to 8% mineral oils and additives, and about 95% water. They are also known as "Ninety Five, Five" fluids.

Semi-Synthetic Fluids
Category Descriptions and Applications
Semi-Synthetic Fluids: Chemical Emulsions

They are concentrates which will be mixed with water at ratios within 10:1 to 20:1 with a high emulsifier content yielding a smaller oil globule, a micro-emulsion, and the fluid will be translucent. They have better wetting characteristics and provide better lubricity at tool bit and workpiece interface than Synthetics. Typically, they do not create mist or smoke during operations. But the water hardness must be controlled becasue hard water can lead to scums and precipitates. The final translucent semi-synthetic cutting fluid consists of about 2% petroleum oil and additives and the remaining is water. They are commonly being used in high speed surface machining operations.

Synthetic Fluids: Chemical Solutions

They are clear and real solutions. The fluids are concentrates which will be mixed with water at ratios within 10:1 to 200:1 without containing petroleum oil. Their lubricity are enhanced by wetting agents. They are stable with hard water and provide excellent microbial control. Their nature are stable, and having superior settling and cooling properties with low mist formation which enable them to be good at high production rates.


Bio-Deterioration Of Metalworking Lubricants

Water-containing fluids are more easier to be deteriorated by bacteria and fungi. Biocide can be added in some soluble lubricants. Mineral oils, metabolic wastes and water inside the lubricants can promote bacteria to growth quickly. One billion bacteria can form a colony that will only be ⅛ inch (3.2mm) diameter. They excrete organic acids which can etch metal surfaces. The byproducts of such deteriorations can make the emulsions unstable, pluggin the filter and creating unpresent odours. The situation will be obvious after the system shut down for one week. By using test kits, the cell enumeration can be monitored and the bacteria growth can be controlled.


Metals, Lubricants And Machining Quality

5 Major Elements In Machining Quality

  • Metal
  • Machine
  • Metalworking Fluid
  • Tooling & Operational Variables
  • Operator

Metals

The cutting fluid required for some common steels are as follows:

Metal Description Cutting Fluid Required
Stainless Steel

They have chromium and nickel content between 12% to 40%. They are generally hard to be machined.

Highly formulated fluids

Tool Steel

They are alloyed steel which are generally difficult to be machined, but they can also assist in machinability in some cases. Grinding is one of the most common operations of these alloys.

Conventional soluble oils

Cast Iron

They contain more than 2% carbon, the excess of carbon exists as graphite inside iron which are generally easy to be machined, and can operate dry machining.

Soluble oils to cool down the workpiece

Zinc

They are very soft metals which are commonly being used in die-casting.

Low viscosity mineral oils as cutting fluids

Magnesium

They are very soft metals which are easy to be machined.

Low viscosities straight mineral oils can be used. However, soluble oils must NEVER be used because magnesium in the presence of water can lead to explosions!

Copper & Alloys

These copper alloys (e.g. brass, bronze, etc.) can stain the finish. Dry machining is available.

NO extreme pressure (EP) additives should be added in the fluid


Forming & Drawing Lubricants

In many industries like automotive and appliance manufacturing, lubricants are necessary media to control frictional stresses, adhesive and abrasive wearings between the die and the workpiece in the metal parts forming and shaping processes.

Lubricant Description & Functions
Forming (Rolling) Oils
  • In general, these mineral based oils have good lubricity and anti-wear characteristics enable them to resist foaming and corrosion
  • They can also be used as cutting and machining oils
  • Aluminum rolling oils are paraffinic solvent-like mineral oils having very low viscosity
  • Copper or bass rolling oils are ISO 32 paraffinic oils containing lubricity additive and no active sulphur
  • In the forming and shaping processes, water miscible, semi-synthetic and synthetic lubricants are usually being used
  • In steel cold rolling operations, water miscible coolant containing 98% water emulsified with mineral oil with extreme pressure additive and emulsifiers can be used
Drawing Oils
  • Specialized for drawing of wire, ferrous metal shapes through dies and the punching of heavy gauge plate
  • Protect against scoring and galling, and enhance finish without the need of further machining processes
  • For aluminum drawings, ISO 320 polar oils with fatty friction reducers can be used
  • For ferrous drawings, ISO 100 paraffinic oils with sulphur, extreme pressure additives, oiliness and anti-rust additives can be used

Rust Protective Fluids

Many industrial components, raw materials and finished products need to be stored. Therefore, rust protective fluids are important to protect them. The material need to be preserved, preservation durations and the storage environment are the main concerns in the selection of the fluid.

Lubricant Description & Functions
Hot Dip Products
  • For long-term storage of component in adverse conditions
  • Dip components into the hot fluid. A tough and reliable coating will be gelled after cooling
Concentrates
  • They are oil soluble which require mixing with the base lubricant. e.g. engine, hydraulic, circulating system oils, etc.
  • About 2% to 5% in concentration after mixing
  • Display water, making the internal surfaces moisture resistance
  • Clean and disperse both soluble and insoluble materials in the system
  • Can have over 2 years of protection
Rust Preventative Oils
  • They are light mineral oils
  • Can be applied to components directly, or applied be spray, misting or brush
  • Protect parts in the indoor environment
  • Commonly used in steel industry as slushing oil. Whey they apply to cold rolled sheets, the lubricant have to be non-staining
  • Usually easy to be removed for further manufacturing operations
  • Suitable for the protections of facilities using circulating or hydraulic oils. e.g. turbines, hydraulic systems, pumps, gear cases, etc.
Solvent Cutback
  • Protects components in the indoor environment during manufacturing operations
  • Can be applied without heating. A thin, translucent film will be formed after the solvent evaporates
  • Can be applied frequently to assist protections against fingerprints and corrosive environment during the manufacturing operations
  • Can be applied by brush, spray or dipping at room temperature

Quenching Oils For Thermal Treatments of Metals

In the thermal treatment process, the characteristics and the functions of quenching oils are:

  • They are usually ISO 15 or ISO 32 graded paraffinic oils
  • They are used to control cooling of steel parts after heat treatments
  • Quenching systems have large reservoirs which making the components to be quenched by the oil but not overheating the oil
  • In general, quench oil system are maintained within 50℃ to 90℃