Emulsion
Emulsions are the most common fluid used for metalworking. Emulsions are the combination of water and concentrate of mineral oil, synthetic ester, emulsifier and some additives. The milky white substance formed by mixing this concentrate with water is emulsion. The components of this concentrate vary according to the process and the metal. Emulsions are also known as Coarse Emulsion and Microemulsions.
Cutting Oils
Cutting oils are one of the types of lubricating oils. They are made up by mixing low viscosity base oils with other vegetable and animal oils, antioxidants, anti- wear agents and rust inhibitors. Cutting oils are not needed to be changed regularly as they are used in the processing of machined parts. However, they need to be refilled constantly. The only situations when they should be changed is when the oil starts to oxidise or a problem of sedimentation starts occurring. Cutting oils can be applied on machines using a method called minimum lubrication in which the oil is sprayed in the air in small quantities and then applied to the machine under high temperatures.
Composition and Characteristics of Cutting Oils
Cutting oils are considered as neat oils as they are made up of highly refined materials. They are used in undiluted form and often prove advantageous for the requirements of the machine. The composition of cutting oils mostly contains mineral, synthetic or semi-synthetic base oils. These base oils build a stable foundation and the additives used with them improves their performance. Some of the unique characteristics of those additives are protection from extreme pressure, resistance to corrosion, anti-wear properties, etc.
Application of Cutting Oils:
Following is some of the applications of cutting oils:
- Lubrication: Cutting oils are known for providing amazing lubrication to the cutting tool and the workpiece. The nature of cutting oils is undiluted which assures consistency of lubricating film and reduces wear and friction. It also benefits for increasing longevity of the tool and improves the quality of machines.
- Extreme Pressure: The exclusive composition of cutting oils help them to bear the high-pressure environments without any difficulty. Thus, they are considered an ideal choice for metal forming or heavy-duty machining. The additives used in the cutting oils protect it and reduce the chance of tool and workpiece damage.
- Versatility: Cutting oils have a lot of versatile properties such as turning, milling and drilling. Thus, cutting oils are suitable for water based cutting fluids due to its adaptability as in this scenario higher degree of lubrication is needed.
Cutting Fluids
Cutting fluid is fluid made up by diluting oil in a lot of water. The percentage of oil in this fluid is around 5 to 20% whereas the percentage of water is about 95 %. Those water-based fluids are later divided into different solutions such as emulsions, microemulsions and chemical aqueous solutions.
Composition and Characteristics of Cutting Fluids
Cutting fluids are specially designed to lubricate, cool down and improve the performance of metalworking operations. The main functions of these fluids are improving the performance of the tools by adjusting the friction, dissipating heat and equipping them with chip evacuation. Cutting fluids are a composition of base fluids such as mineral oil, water and additives which makes these fluids corrosion resistance, lubricative, etc.
Application of Cutting Fluids
Following is some of the applications of cutting fluids:
- Cooling: One of the important functions of cooling fluids is to cool down the metal and maintain the minimal temperatures. Cutting fluids minimizes the extreme heat generated during the machinery processes which increases the safety and lifespan of tools.
- Lubrication: The lubrication properties of cutting fluids are useful in minimizing the fiction between the tool and the workpiece. This minimization of friction smoothens the operations and modifies the wear on both of them. The benefits of these lubrication properties are longer lifespan of the tools, improved finished surface and accuracy in dimensions.
- Chip Evacuation: Cutting fluids are really useful during the operations like drilling and milling in which buildup of chips is difficult. They help in removing the chips or swarf proficiently and protect the machines from chip interference. This leads to continuity and precision in the operations.
Difference Between Emulsions, Cutting Oils and Cutting Fluids
Following is the difference between emulsions, cutting oils and cutting fluids:
- Composition: The composition of all 3 substances is different from each other. Emulsions are made up of water and a mixture of mineral oil, synthetic ester and additives. Cutting oils are mineral-based made up of oils and additives. Cutting fluids are water-based, made up of water, oil and additives.
- Water Solubility: Emulsion have a hydrophilic end due to which they are soluble to water. Cutting oils are not soluble to water as they do not contain water in their composition. They are used undiluted. Cutting fluids are soluble to water and are diluted for the required operations.
- Cooling Ability: Emulsions do not have an ability to cool the process and maintain the temperatures. However, they do have heat reduction properties. Cutting oils do provide excellent lubrication but they have low capability of heat dissipation. Cutting fluids consists of high capacity of temperature management due to their water content.
Take Away
This is the brief explanation about emulsions, cutting oils and cutting fluids along with the key differences among them. We hope this information will be effective for you. Please let us know through your valuable feedback and the suggestion in the drop box.