High-speed cutting puts high demands on the cutting fluid. The selection of high-quality cutting fluid can better ensure the smooth processing. The rational chemical management can prolong the service life of the cutting fluid and reduce the consumption, thus reducing the comprehensive cost of cutting fluid. .
High-quality cutting fluid improves cutting efficiency
High-speed cutting means large feed rates and higher machine spindle speeds. Increasing the unit feed rate means that the processing load is increased, and the processing fluid is required to have stronger processing (lubrication) ability and coldness ability to reduce the heat generation during the cutting process and the deformation of the workpiece, and reduce the energy required for the cutting process. This may require high pressure, high flow coolant pumping. Increasing the spindle speed means that the tool or workpiece line speed is increased. In the case of high flow and high pressure pumping, the impact agitation will bring more gas into the cutting fluid, resulting in foaming tendency, and the tank design of modern machine tools. More and more compact, the defoaming time of the processing fluid is also shorter and shorter, which poses new challenges to the anti-foaming and defoaming ability of the processing fluid.
The high-quality cutting fluid has good anti-foaming performance and water quality adaptability, which ensures the high-speed cutting smoothly. The processing of certain auto parts, such as steering gears and crankshafts, requires the use of oily cutting fluids. The high temperatures and shocks caused by high-speed cutting may atomize the oily cutting fluid. These oil mists floating in the air will affect the workshop. The operating environment and the physical and mental health of the work, the drift of the oil mist also means the loss of oil. Through the optimization of base oil and anti-oil mist additives, Total's researchers have successfully reduced the amount of oil mist generated by more than 60%, reducing the generation of oil mist from the source and reducing the negative impact of cutting fluid on HSE. At the lowest level, the cutting fluid consumption is reduced and the cutting cost is reduced.
Chemical management reduces the overall cost of cutting fluid use
For now, the core of chemicals management is coolant management. Taking an engine factory as an example, the current engine factory mostly uses a centralized liquid supply system. The whole system capacity can reach 300-500 cubic centimeters, and only the initial concentrate concentrate can be used up to 20-30 tons, and the whole system service life requires 2 years. Above, this puts high demands on the management and maintenance of the entire system. We know that in the process of using metalworking fluid, there will be a lot of miscellaneous materials such as rail oil, spindle oil, hydraulic oil and iron filings mixed into the cutting fluid, which contains a large number of microorganisms, and these substances are microbial reproduction. The root cause of the odor of the cutting fluid is that the microorganisms grow and multiply in the cutting fluid. The proliferation of microorganisms in the cutting fluid can have very serious consequences, such as producing foul odor, deteriorating the environment and affecting human health; consuming additives and oily agents in the cutting fluid, reducing the lubricating performance of the cutting fluid, affecting the processing quality of the workpiece; bacterial metabolism The resulting acidic material destroys the stability of the cooling, and the proliferation of the fungus can also block the pump, the sedimentation tank and the filter. In order to prevent spoilage and deterioration in the use of the cutting fluid, it is important to enhance the subsequent management of the cutting fluid while improving the antibacterial ability of the cutting fluid itself.
The processing of large quantities of iron parts places high demands on the rust resistance of cutting fluids. Especially in the hot rainy season, the detection of coolant rust resistance will be a very important part of coolant management. Avoiding rework of workpieces due to rust is equivalent to increasing production efficiency.
It can be seen from the above two points that the maintenance of cutting is not a simple matter. Based on experience, the author puts forward the following suggestions for the use and management of cutting fluid:
1. The management of the coolant is best handled by a specialized chemical management company or coolant supplier, freeing itself from the management of the coolant and focusing on its core business. It is best to assign a person who is not qualified to manage the coolant.
2. A professional company helps to choose the most suitable product.
3. Use post-management to remove oil slick, control concentration (daily detection), pay attention to PH value, microbial content detection (weekly detection and release of bactericide according to test results), pay attention to detection of cutting fluid rust resistance (weekly inspection Increase the detection frequency when the weather is humid.)
Through the above management measures, the processing enterprise can greatly extend the service life of the cutting fluid, reduce the consumption of the coolant, reduce the discharge of waste liquid, improve the processing precision of the workpiece and the product qualification rate, and achieve the purpose of improving efficiency, reducing cost and increasing efficiency.
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