METALWORKING FLUIDS
Innovative set-up for tribo-screening of metalworking fluids and coolants
Ameneh Schneider and Felix Zak, Optimol Instruments Prueftechnik GmbH, Munich/Germany Motivation
The coolant system for metalworking is a typical example of a tribomechanical system, where several wear mechanisms are present simultaneously. Additionally the formulation of metalworking fluids (MWFs) must meet many different criteria and overcome a number of challenges, such as environmental and health & safety considerations, corrosion, staining, formulation stability, foaming, and fluid longevity. Metalworking particulate composition varies significantly depending on the cutting process and operating conditions, as well as coolant characteristics and coolant systems.
In 2002, the authors stated that the workpiece (and its relative machinability), and tool materials can vary greatly, and there are a multitude of different machining processes that can be utilised (among them, milling, drilling, grinding and broaching), each with their own fluid needs [1]. More recently, in 2022 - twenty years after the initial statement - the authors also concluded that the greatest challenge is the machining of ferrous and non-ferrous alloys with a single MWF [2]. Metalworking fluids are complex, and can be mineral-oil-based, synthetic- based, semi-synthetic or water-based (emulsion). The greatest challenge will be to find the right type of Anti-Wear (AW) and Extreme Pressure (EP) additive to work with both ferrous and non-ferrous alloy. For example, an additive which may be effective on a ferrous alloy may be antagonistic to a non– ferrous alloy and vice versa. For these reasons, measuring the tribological performances of different
formulations will give more insights about the lubricity and protection performances of MWFs.
Optimol Instruments has developed a new machining set-up, in co-operation with industry partners, for meeting these challenges, helping MWF manufacturers to develop high performance coolants and MWFs for the future.
Design of set up for fluids with high flow rates and high rotary velocities for SRV® modus
rotation
As can be seen in Figure 1, the fluid will be supplied directly into the cutting area using a nozzle. It is possible to add an additional temperature sensor in the fluid drain. Through using this set-up in the rotation modus of SRV® 2000 rpm are achievable.
, high rotation speeds of up to
Figure 1: Cross section of construction design.
Lower disk specimens, a fluid bath, different holders for variable contact geometry (point, line, area) and a fluid pump are included in this set-up (see Figure 2).
Continued on page 25 LUBE MAGAZINE NO.174 APRIL 2023 23
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