MWF Training
MWF Training
Training
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Contents
➢ Part 1 – Industrial Oils
➢ 1.1 Hydraulic Oil
➢ 1.2 Slideway Oil
Hydraulic Oil
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Types of Hydraulic Oil
United Vesta Hydraulic Properties
H Zinc-based; Antiwear
HX Zinc-free; Ashless
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Part 1.2
Slideway Oil
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Primary Function
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Primary Requirement
➢ Pass demulsibility test (ASTM D1401)
➢ Pass Cincinnati Machine performance level (P-47 for ISO 68
viscosity) – stick-slip test
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Part 2
Metalworking
Operations
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Types of Operation
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➢ Broaching
➢ Hobbing
➢ Gear Cutting & Shaving Heavy
➢ Tapping & Threading
Severity ➢ Honing
➢ Reaming
Of
➢ Form Grinding
Machining ➢ Deep Hole Drilling
Operation ➢ Multi Spindle Autos
➢ Milling
➢ Turning
➢ Drilling Light
➢ Grinding
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Metalworking Process Severity
➢ Light – Medium Duty
➢ Grinding, Turning, Milling, Boring, Threading, etc.
➢ Heavy Duty
➢ Drilling, Reaming, Tapping, Gear Hobbing, etc.
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Grinding Process Severity
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Grinding / Honing
Drilling
Boring
Reaming
Tapping
Drilling, Tapping, Boring
Turning
Milling
Grooving / Cut Off
Threading
Threading
Gear Hobbing
Making a Gear
Broaching
Broaching
Types of Metal
Ferrous vs Non-Ferrous
➢Ferrous
➢ Metals which contain Fe → Iron
➢ e.g. Steel, Stainless Steel, other Iron Alloy
➢Non-Ferrous
➢ Any metal or alloy that does not contain Iron.
➢ e.g. Brass, Copper, Bronze, Aluminum and etc.
➢ Also known as Yellow Metal.
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➢ Titanium Alloy
➢ Nimonic
➢ Inconel
➢ Nickel
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Part 3
Metalworking Fluid
Basics
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Basic Functions of Cutting Oil
➢Cooling
➢ Dissipates heat
➢Lubricating
➢ Reduces friction
➢ Better finishing
➢ Extends tools’ life
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Basic Functions of Cutting Oil
➢Chips/Swarf Flushing
➢ Remove chips / swarf to sump
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Cutting Oil Categories
➢Neat Oil
➢To be used straight / as it is
➢Soluble Oil
➢Also known as cutting coolant
➢To be mixed with water before use
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Viscosity of Oil
➢Viscosity → resistance to flow of a fluid
➢Unit of viscosity
➢ Centistokes (cSt)
➢ Define at specific temperature (e.g 40 deg C)
➢ Example at room temperature:
➢ Gasoline = 0.5 cSt
➢ Water = 1 cSt
➢ Olive Oil = 80 cSt
➢ Ketchup = 100,000 cSt
➢ Peanut Butter = 250,000 cSt
➢ Neat Cutting Oil – Typical Range: 10 cSt to 50 cSt @ 40oC
➢ Forming Oil – Typical Range: > 40 cSt to > 10,000 cSt @ 40oC
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Viscosity Influence
Cooling &
Lubricity
Flushing
Viscosity Viscosity
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Properties – Neat vs Soluble Oil
Neat Oil Soluble Coolant
Cooling / Flushing
Lubrication
House Keeping
Fluid Maintenance
Cost Effective
Part Finishing
Corrosion / Rust
Protection
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Part 4.1
Soluble Oil
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Soluble Oil Components
➢Emulsifier
➢ Emulsify oil into water (oil soluble coolant)
➢Anti-Microbial
➢ Kills/prevents growth of germs
➢ Either biocide or fungicide or combination
➢ Added in fluid formulation or post treatment of system
➢Defoamer
➢ Significantly reduces foaming potential
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Coolant Maintenance
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Coolant Maintenance
➢Water Quality
➢ The inorganic salts in water will affect the coolant stability and
foaming
Ideal Water
Hardness (calcium
carbonate) appx 100-
200ppm
Chloride zero
Sulfate zero High Salts
Soap formation
Low Salts
Coolant
Excessive instability
foaming
Corrosion
Bacterial attack
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Coolant Maintenance
➢Coolant Concentration
✓ Always maintain the recommended
concentration
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Coolant Maintenance
➢pH Reading
4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0
soluble
oils
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Coolant Maintenance
➢Machine Cleanliness
✓ Use skimmer to remove tramp oil
✓ Routine house-keeping
✓ Very important as it affects Coolant life
Tramp Oil Skimmer
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Common Coolant Issues
➢Rancidity / Smell
➢ Caused by bacteria
➢ From sump that contain chips, swarf, tramp oil, sludge & etc
➢Rust
➢ Bacteria increase, pH drop from alkaline to acidic level
➢ Desirable pH should be between 8~10
➢ Too high pH will cause stain particularly on Aluminum
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Common Coolant Issues
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Common Coolant Issues
➢Excessive Foam
➢ Depletion of anti-foam in coolant. A very small dose of anti-
foam on tank side will solve the problem.
➢Concentration Control
➢ Water will evaporate and lead to higher concentration drag
out. Hence higher cost.
➢ Insufficient concentration will affect cutting performance as
well as tools life.
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Soluble Oil / Coolant Types
➢Mineral (usually called Soluble Oil)
➢ 100% oil, combination of base oil and chemical ingredients
➢ High oil content, forms milky emulsion
➢Fully Synthetic
➢ No oil content, 100% chemical ingredients
➢ Forms transparent emulsion
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Typical Questions to Ask
Soluble Oil / Coolant
1. Current product being used?
2. Milky or translucent or transparent type?
3. What is the process?
4. What is the material?
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Part 4.2
Neat Oil
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Neat Oil Components
➢Base Oil
➢ Highly refined oils of high, medium and low viscosity
➢ Hydro-treated, hydro-cracked oils that provide excellent
oxidation stability
➢Lubricity Agents
➢ Natural fats
➢ Natural plant ester
➢ Synthetic ester
➢Corrosion Inhibitors
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Neat Oil Components
➢Extreme Pressure (EP) Additives
➢ Fatty Oils (Effective 100oC- 150oC)
➢ Chlorinated paraffin (Effective 250oC- 450oC)
➢ Phosphorous (Effective 350oC- 400oC)
➢ Sulfur (active / non active) (Effective >600oC)
➢Anti-Wear Agents
➢ Zinc dialkyldithiophosphates (ZDDP)
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Neat - Cutting Oil Types
➢Cutting
➢ Eg. Turning, milling, drilling, tapping, threading, broaching, etc.
➢ Oils without Extreme Pressure (EP)
➢ Oils with EP
➢ Chlorinated
➢ Sulfurized (Active/Inactive)
➢ Mixture
➢ Non-traditional EP
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EP - Sulfur Additive
➢Active vs Non Active
➢ Sulfurized additives being used as EP in oil.
➢ Copper Corrosion test (ASTM D130)
➢ Active → WILL stain yellow metal
➢ Non-Active → WILL NOT stain yellow metal
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Typical Questions to Ask
Neat Oil
1. Current product being used?
2. Any issues faced with current product?
3. What is the process?
a) Process details, production video, pictures?
4. What is the material?
5. Is lubricant allowed to contain chlorine?
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Part 4.3
Forming Oil
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Neat – Forming/Drawing Oil Types
➢Forming/Drawing
➢ High viscosity oils
➢ Typical KV: 60 cSt to > 10,000 cSt
➢ Usually contains high EP content
Drawing
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Fast Stamping
Progressive Die Stamping
Rolling
Forging
Basic Functions Of Forming Oil
➢ Cooling
➢ Dissipate heat
➢ Lubricating
➢ Reduces friction
➢ Better finishing
➢ Extended tools life
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Types Of Forming Oil
➢Medium Range Hydrocarbon Fluids
➢ Example: Kerosene & White Spirits
➢ Mostly self-drying, but may take up to 48 hours
➢ Low to medium EP & Lubricity
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Types Of Forming Oil
➢ Oils For Hot Forming
➢ Low to medium viscosity
➢ High oil content
➢ Generally content very high EP & Lubricity properties.
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Typical Questions to Ask
Forming Oil
1. Viscosity of current product?
2. What is the process?
a) Initial and final shape of item (pictures if possible)
3. What is the material?
4. If stamping
a) Fast or slow stamping?
b) Need fast evaporating oil?
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Part 4.4
Quenching Oil
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Primary Functions
➢Hardening of steel
➢ Facilitates hardening by controlling heat transfer (or cooling
speed) during quenching
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3 stages of Cooling Curve
Monitor of Quenching Oil
➢Viscosity
➢ Oil viscosity may change over time due to degradation and
hence affect the performance
➢Water Content
➢ Water from contamination or degradation may cause soft
spots, uneven hardness, staining and even fire.
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Monitor of Quenching Oil
➢Flash Point
➢ For safety precaution, the minimum flash point under normal
operating conditions should be 90 deg C ABOVE the oil
temperature being used.
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Monitor of Quenching Oil
➢Sludge Formation
➢ The presence of sludge may cause uneven heat transfer,
increase thermal gradients and increased cracking and
distortion.
➢Elemental Analysis
➢ Element within additives used will deplete over processes.
➢ Fresh oil and used oil analysis will provide good comparison.
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Monitor of Quenching Oil
➢Cooling Rate
➢ ASTM D 6200 – Cooling Curve Analysis
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Monitor of Quenching Oil
➢Cooling Rate (time taken to reach 200s)
➢ Fast 10 – 25 sec
➢ Medium 26 – 34 sec
➢ Slow 35 – 40 sec
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➢Cooling Rate
➢ Alternative test: GM Nickel
ball test
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Typical Questions to Ask
Quenching Oil
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Part 4.5
Rust Preventive
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Primary Functions
➢ Forming a barrier between metal surfaces and
contaminants such as air, water and other corrosive
materials.
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Application
➢ Dipping
➢ Spraying
➢ Flushing
➢ Brushing
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Primary Properties
➢ Water displacement (dewatering) (DWF)
➢ Acid neutralizing
➢ Easy apply and easy removal
➢ Resistance to moisture penetration
➢ Resistance to weathering
➢ Non-staining
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Common Product Types
➢ Solvent Base
➢ Oil Base
➢ Water Base
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Common Tests
➢ Humidity Cabinet, ASTM D1748
➢ Simulated testing for indoor storage
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Typical Questions to Ask
Rust Preventive
1. Protection length
a) No. of weeks, months, years?
2. Protection condition
a) Indoor or outdoor?
3. Product type requirement?
a) Solvent, oil or water-based product?
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