Metalworking Fluids, Second Edition

This book is an update to a 1994 book that have become recognized a primary resource for professions using metalworking fluids (MWFs). The book has been cited by the Society of Tribology and Lubrication Engineers (STLE) in the its Body of Knowledge and recommended to students taking the exam for Certified Metalworking Fluids Specialist. Notable updates to the 1994 edition are sections on microbiology, waste management and government regulations. In addition to covering the basics and being a textbook for students of fluids, the book includes details of trends and facts not commonly known to those outside the fluids industry.

Though contents of the books focus upon fluids, grinding applications figure prominently in this book because grinding is one of the major end uses. Uses of metalwlorking fluids are influenced by safety, environmental and economic issues as well as many other nonperformance issues. This is well illustrated by preference for water-based fluids in the US even though oils have a clearly known performance advantage in application worldwide.

Though many of contributors to the book represent manufacturers of metalworking fluids, the book offers are honest presentation of the complex issues that confront users of the essential resource for industry.

Table of Contents

• In the book's introduction consultant Jeanie McCoy surveys the milestones in development of metalworking fluid (MWF)that include the work of Milton Shaw. Shaw's research demonstrated the impact of high temperatures and pressures at the cutting interface on chemical reactions involving the fluid and workpiece. Such reactions create a solid film film on tool and work surfaces that can be friction-reducing elements. Subsequent research on chemical additives led to development of CIMCOOL.
  
   


• In the chapter on filtration Robert Brandt writes that the generally accepted equilibrium level of fines for grinding of steel is about 12 ppm of suspended particles with an average size of 10 micron. However current research suggests that industry should be paying more attention to sizes of 3 to 8 micron. He also says that while advances in electronic for filtration equipment in the last decade provide better convenience for operators, the basic technologies behind filtration remain unchanged.


• When discussing the basics of metallurgy, James Denton reports that of the 100 stable element recognized in the periodic table, all but 25 are metals. Most common metals are combinations or alloys of those elements. Iron and steel so dominate applications that metals are classed as ferrous and nonferrous materials. Grain structure, hardness, surface finish are the most important features of metallurgy affected by MWFs and machining.
  
   


• For fluid performance in grinding operations,Cornelius Smits, Tech Solve describes the relationships between material removal rates and grinding efficiencies as exponential functions where changes in one variable has a nonlinear effect upon the other. He also says the differences in chip sizes and shapes between large OD and small OD parts require different strategies for filtering fluids. Filtration does not remove very small particulate and 5 micron particulates remain suspended in the fluid to accumulate and contaminated the fluid. Temperatures of the fluid can have dramatic effects upon fluid performance. G-ratios can be dramatically change when fluid temperatures rise above 32 ° C. Also high thermal conductivity of superabrasives requires special attention to heat extraction for resin bond grinding wheels to extend the life of the grinding wheel.
  
   


• According to Frederick Passman in the chapter on the microbiology of fluids there have been many advances in molecular biology over the last two decades, but the newer methods have rarely been applied to metalworking fluids. Even though, only 0.001% of all microbes have been isolated and identified, traditional methods for controlling microbes has served industry well. Since it is impracticable to prevent microbe inoculation, the best option is to control microbe growth through recognized practices.


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