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  5. A BEGINNER’S GUIDE TO CUTTING FLUID

A BEGINNER’S GUIDE TO CUTTING FLUID

Ideal cutting fluids must be health, safety, security & environmental (HSSE) compliant. The fluids operating economy must be high while its cost should be low.

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According to the 2021 State of Manufacturing Report, machine manufacturing is seeing a 25% to 50% surge. This means that machines will have to work harder to manufacture goods to feed the demand. 

 

Because of this rising demand, manufacturers are now compelled to use high-quality, preferably water-soluble cutting fluids. Not only do they increase the efficiency of the machines' performance, but they also protect them from corrosion. Hence, having a thorough knowledge of these cutting fluids has become all the more important.

 

Ideal cutting fluids must be health, safety, security & environmental (HSSE) compliant. They should be selected based on the existing metallurgy of the machine and its components. The operating economy of cutting fluid must be high while its cost should be low.

 

Types of cutting fluid

 

There are several types of cutting fluids, but most can be categorized into three general groups:

  1. Solubles
  2. Synthetics
  3. Semi-synthetics

 

Each one has specific properties that render the fluid ideal for particular machines.

 

1. Water-soluble cutting fluid

 

Water corrodes machinery and is not a lubricant. Hence, water-soluble cutting fluids must be added to them to provide protection from corrosion. These cutting fluids are called coolants.

 

Emulsifiers are the most popular variants of solubles. Emulsifier cutting fluid is made by adding mineral oil and other additives to the concentrate. These additives control undesirable properties like foaming and rusting while enhancing performance under conditions like extreme pressure.

 

Despite all the additives, solubles are not the most desired fluids for ferrous machines and components. The most noticeable downside of soluble cutting fluids is the bad odor. Emulsions have poor bio-resistance. If not stored properly, they are prone to fungal and microbiological growth, resulting in a foul odor.  

 

Additionally, they have low bio-stability and cannot maintain their composition well. The result is that the oil separates, which eventually renders the fluid ineffective as a coolant. 

 

Another noticeable aspect of solvents is the residue. These cutting fluids leave behind a sticky substance after prolonged use, making the machinery look unkempt and dirty.

 

2. Synthetic cutting fluid

 

Synthetics are the opposite of emulsions. While emulsions have mineral oils, synthetics are oil-free and do not contain any esters. Instead, they contain chemicals and polymer compounds that bring all the benefits that mineral oils have to offer.

 

These cutting fluids are used in heavy-duty machinery that operates at high speeds and generates significant heat energy. They consist of water mixed in organic and inorganic compounds and are excellent coolants.

 

Synthetic cutting fluids are versatile and can be customized for any machinery. They are most commonly used in machines utilized for grinding operations. Of all the types of cutting fluids, synthetics are the best coolants. Castrol has some of the best synthetic fluids that protect the equipment and improve performance. 

 

Synthetic cutting fluid is on the expensive side when it comes to cost. Many compounds used in making synthetics come from crude oil. So, crude oil price fluctuations directly impact synthetic cutting fluids' prices.

 

Synthetics need care for storage and disposal as they can turn hazardous if not handled properly. Finally, they can only be used on ferrous metals.

 

3. Semi-synthetic-cutting fluid

 

As the name suggests, semi-synthetic cutting fluids are a mixture of soluble and synthetic variants. They contain synthetic compounds and polymers, a type of soluble called emulsifier, and a base, typically a mineral oil or petroleum. Emulsifiers in semi-synthetic cutting fluids help in holding the lubricants in the fluid.

 

Since semi-synthetic cutting fluids contain water, they are excellent coolants. Because of the emulsifiers, they provide superior lubrication. The synthetic compounds protect the metal parts from rust and corrosion. 

 

Semi-synthetics can also have varying formulas, increasing their versatility. Unlike the synthetic and water-soluble variety, semi-synthetic cutting fluids can be used on both ferrous and non-ferrous metal machinery.

 

New research and innovation are making semi-synthetics into high-performance formulas for machines with extreme speed and heat.

 

Water is the enemy of semi-synthetics. If not maintained well, these cutting fluids can become unstable or generate foam. Hard water will break down the compounds and emulsions, causing it to lose the ability to lubricate.

 

Since semi-synthetics are a combination of soluble and synthetics, they inherit the vulnerability of bacterial growth. They need proper maintenance and specific storage conditions for longevity.

Also read

Cutting fluid complete guide

 

Conclusion


According to Global Market Insights, the cutting fluids business is expected to become a $15 billion market by 2025. This means the use of cutting fluids will only grow as the demand for various goods continues to increase in the world.


The three areas where cutting fluids will change in the future are:

  • They will become more sustainable.
  • They will be less hazardous for workers.
  • They will be exponentially more effective with fewer quantities needed.

Castrol is already leading in this area by providing the right balance of cutting fluids that are high performance and respect sustainability. With the expected growth in the manufacturing industry, choosing the right cutting fluids is essential. The correct fluid will improve efficiency and protect machinery from wear and tear.


The ideal fluid must be non-corroding, versatile, non-contaminating, and resilient, just like Castrol. 

 

RUSTILO HAS A WIDE RANGE OF PRODUCTS THAT ARE CATEGORICALLY DIVIDED AS FOLLOWS:  

 

Smell-free rust preventive:

  • Rustilo DW 300 X
  • Rustilo DW 310

High-flash point rust preventive:

  • Rustilo DW 250 HF
  • Rustilo DW 270 HF
  • Rustilo 630Rustilo 
  • DW 205

Waxy film rust preventive:

  • Rustilo DWX 30
  • Rustilo DWX 32 VAL
  • Rustilo DWX 32
  • Rustilo 401 C

ROily film rust preventive:

 

  • Rustilo DW 902
  • Rustilo DW 901
  • Rustilo DW 904

Dewatering solvent:

  • Rustilo DW 950 

 

Rustilo is one of the best rust preventive products available in the market. Rustilo comes from the house of Castrol, one of the leading lubricant manufacturers in India.
 
With Rustilo, you will have the best on-site support team. The technical experts of Castrol have decades of experience and are competent to find solutions to complex technical challenges.
 
Castrol also excels in conducting on-site training programs for loyal customers to share and impart best industrial practices and product USPs to optimize operating costs. You will be part of this knowledge sharing wherever you may be.
 
Explore the high-value products of Castrol.

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