How to reduce costs in soluble cutting fluid systems
By: Luis Morales - Industrial Application Manager
1. Keep a good record of data
Normally companies do not know the costs of their products in machines; they usually know the cost per liter when buying new product and the cost of providing it but cutting fluids can affect production costs in other ways.
Companies make the right decision when keeping track and track that allows them to ensure that the cutting fluid is in the right condition for their operations.
2. Tool life
The frequency of sharpening and replacement of worn tools is directly related to the effectiveness of the cutting fluid in the machine. A cutting fluid itself, with good maintenance and good cleaning practices can double and sometimes triple tool life.
3. Surface finish
This is intimately linked to the life of the tool that is produced in machined parts. A poor finish is usually due to inadequate lubrication or corrosion resistance by the cutting fluid being used. The RIGHT product will produce correct, good quality and stain-free finishes.
4. Production range
The right cutting fluids give the right touch to the equipment that works with them. Production is reliable and predictable. In contrast, an improperly formulated fluid or a "dirty" cutting fluid can affect production with many unpredictable variations and data.
5. Dead time
The frequency with which equipment requires to be adjusted and calibrated to give the desired dimensional tolerances, sharpening and replacement of cutting tools, as well as cleaning the cutting fluid filtration system can increase when the appropriate cutting fluid is not being used.
6. Storing empty drums is expensive
These containers can be recycled having some third party reusing them, other than these can be used as dumpsters, previously opened from the lid and identified (it is recommended to drill to the bottom to avoid their water storage reuse. or you can make use of a drum compactor for disposal as a iron in some local scrap collector.
7. Disposition
The cutting fluid disposition volume is directly related to the number of times it is used. Each time the cutting fluid is reused, disposition costs are reduced. This cost reduction should be considered when investing in cutting fluid recycling treatment equipment.
8. Standardize cutting fluids
The use of a cutting fluid formulated for all types of metals and operations is possible. However, using many more types of cutting fluids than necessary can be a problem and lead you to make mistakes. Lubricantes FUCHS Mexico recommends that you do not use more than three different types of cutting fluid. However, you can use different concentrations of the same cutting fluid instead of having a variety of different products. The fewer variations, the better.
9. Buy quality cutting fluid from quality suppliers
Do not purchase low-quality cutting fluids at low cost. Almost always the cutting fluids that we perceive as "expensive", are better as they provide stronger and more stable emulsions, which last longer lubricating and provide much better corrosion protection, typically the purchase price of a cutting fluid is 1/2% of the total machining costs. Trying to reduce these costs when buying a low-cost fluid is not a good idea. Concentrate savings will be bringing you closer to productivity decline, faster tool wear, and increased costs of maintaining the cutting fluid and disposal.
Buy cutting fluids from only one or two suppliers. Seller loyalty is an advantage for you, those loyal suppliers will respond faster when a problem arises.
Most importantly, select vendors that support your products (after-sales service). Supporting suppliers can count on laboratories and measuring equipment for cutting fluids. These vendors also have technical staff able to analyze problems and make recommendations to provide cost-benefit solutions for your business, you alone, could hardly do so.
Lubricantes FUCHS Mexico can help you ensure that your operations are performing as efficiently as possible that you achieve a cost reduction.
10. Use good quality water
Minerals that are present on most of the surface, as well as well water, are very harmful to equipment and machining centers, these react and accumulate within the emulsions of the cutting fluid, forming residues in machines and tools, as well as machined parts which over time end up in corrosion problems.
They also contribute to the increased count of microorganisms in the system (machine) which are responsible for reducing the life of the cutting fluid. To avoid such problems, use water with a low mineral content.
Water hardness is the main component in the form of calcium salts present in water, these can contribute to fluid contamination, however, it is not necessary to have 100% salt-free water as filtration costs would be high.
A water quality with values of 120 ppm hardness (120 mg of calcium salts per lt of water) can give good results without severely affecting the performance of the cutting fluid. However, using water with a hardness from 250 ppm (250mg of calcium salts per liter of water) or higher will simply cause the emulsion to be loaded more frequently due to corrosion problems, emulsion stability (in some cases). and waste formation problems.
The use of water filtered by reverse osmosis or treated with softening systems can help you control the content of calcium and magnesium salts, and other components harmful to your process. We suggest that before you think about installing or purchasing a water treatment system, contact your Lubricantes FUCHS Mexico Sales Representative for better advice.
11. Maintain the concentration and pH of your fluid
80% of the problems generated in a cutting fluid are attributed to pH and/or low concentration. Therefore, it is essential that the cutting fluid (soluble) is kept within the recommended parameters. appropriate advice is also provided to the staff in charge of the maintenance of the soluble. Lubricantes FUCHS Mexico has highly trained staff to provide you with the support and advice you need in your cutting fluids.
12. Prevent contamination of cutting fluid
Organic contaminants in the machine and in the tank are a food source for bacteria and fungi, additionally odors and a drop in pH values will be generated. this will lead to a decrease in the lubricity of the cutting fluid, as well as an increase in the ease of oxidizing metal parts. The best way to avoid microbiological contamination is to keep contaminants away from cutting fluid. The oil in the way is one of the main contributors, so make sure you have the right devices to keep it out of the emulsion.
Continuously review the source of oil leaks and find the right time to correct them, the second harmful contaminant for emulsions is rubbish by the operator, from inserting hands into the fluid to throwing dirty rags, parts and/or food will drastically affect the life of the cutting soluble.
13. Continuously remove contaminants from cutting fluid
Even with best practices, some incurred oil will be present in the machines, as well as fine solids at the bottom of the machine tanks will be continuously accumulating, therefore it is important to remove these materials before they accumulate and begin to degrade and reduce the performance of the cutting fluid.
Fluid recirculation is a primary part of keeping emulsions stable, this activity prevents the development of anaerobic bacteria and the fluid oxygenates preventing microorganisms from depositing into colonies or mushrooms that damage the fluid.
14. Avoid over-use of biocides
Bactericides are poison for bacteria, many even for larger life forms as well. "Strong" biocides are not recommended for routine bacterial control use. Bactericides may become present at the time and time you dispose of the product. Use specific bactericides, as it is much better to use bactericides that limit the feeding of microorganisms. Studies indicate that most bactericides are much more effective when used in shock doses than when used on routine bases. It appears that the bacteria adapt to the repetitive use of biocide or adapts to small doses of biocide (in most bacteria).
At Lubricantes Fuchs de México we are committed to providing you with products and services of excellence.