Table Of ContentMETALWORKING
EDITED BY
JERRY P.
Cincinnati Milacron
Cincinnati, Ohio
Marcel Dekker, Inc. New York. Basel Hong Kong
Library of Congress Cataloging-in-PublicationD ata
Metalworking fluids I edited by Jerry P. Byers.
-
p. cm. (Manufacturing engineering and materials processing
; 41)
Includes bibliographical references and index.
ISBN 0-8247-9201-7
Metal-working lubricants. I. Byers, Jerry P.
11. Series.
TJ1077.M457 1994
67 1 “dc20 94-14919
CIP
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Copyright 1994 by Marcel Dekker, Inc. All Rights Reserved.
Neither this book nor any part may be reproducedo r transmitted in any form or
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permission in writing from the publisher.
Marcel Dekker, Inc.
270 Madison Avenue, New York, New York 10016
Current printing (last digit):
10987654321
PRINTED IN THE UNITED STATES OF AMERICA
Preface
For as long as people have been cutting metal, fluids have been used to aid the
Water may have been the first fluid, followed by animal fats, vegetable oils,
mineral oil-in-water emulsions, and in recent years, by clear synthetic chemical
solutions. Today, a broad range of coolants and lubricants for metalworking continue
to be key components of the manufacturing process around the world. Poopfu lar use
the terms “oilso” r “cutting oils”t o broadly refer to these fluids is inaccurate. The
term “metalworking fluid” will be used here.
This book was writtetno serve the current needs of industry by presenting a
review of the state of the art in metalworking fluid technology, application,
maintenance, testing methods, healtha nd safety, governmental regulations,
recycling, and waste minimization. Older texts tended to ignore or give light
treatment to important operational aspects of the use of fluids for metalworking.
It is hoped that this work will fill these gaps and address new issues that have
surfaced in recent years. The contributors are well-known formulators, physi-
cians, college professors, fluid users, industry consultants, and chemical and
equipment suppliers.
The chapters thatf ollows ummarize the latest thinking on various
technologies related to metalworking fluid development, evaluation, and
application. Chapter traces the historical developmento f the use of lubrication
in metalworking. Because metalworking fluids are used to shape metal, Chapter
2 covers important aspects of the metallurgy of common ferrousa nd nonferrous
metals. Chapters describe fluid application in metal cutting, grinding, and
forming. Chapter explains the chemistryo s f t raight oil, soluble oil,
semisynthetic, and synthetic (nonoil-containing) fluids. Chapter 7 familiarizes
the reader with laboratory methods for evaluating fluid performance. Two
aspects of metalworking fluid performance and evaluation are so important and
complex thats eparate chapters have been devotedt o them: corrosion control and
microbial control (Chapters 8 and 9, respectively). Handling aspects off luid in a
manufacturing facility are covered in Chapters 10-12 on filtration, management
and troubleshooting, and recycling. Disposal of the fluid after a long ulsiefefu isl
covered in Chapter whichd iscussesw astet reatmentp rocesses.P ersonal
concerns of the machine operator are addressed in the chapters on dermatitis
(Chapter and health and safety (Chapter 15). Chapter 16 leads the reader
through the tangled maze U.S. government regulations affecting both the
manufacture and use of metalworking fluids and explains the impact of these
laws on industry. Finally, ac omprehensiveg lossary of over 300 is
included. These terms were supplied by the contributors.
Metalworking Fluids will appeal to a broad readership including machine
operators, plant managers, foremen, engineers, chemists, biologists, and gov-
ernmental and industrial hygienists, as well as to instructors of manufacturing
and industrial disciplines and their students. The authors hope that this text will
help modem industry meet the worldwide demand for improved quality and
productivity in a cleaner environment.
Several employees of Cincinnati Milacron should be recognized for their
contributions to the completion this work. Mr. Ralph Kelly, Dr. William
Lucke, and Dr. Charles Yang reviewed everyc hapter, offering their comments.
Mr. Steven Bridewell spent long hours preparing manyo f the illustrations. Mrs.
Charlene Honroth skillfully and patiently handled communication with the au-
thors and much the typing. Sincere thanks to these people for their help and
dedication.
Jerry P. Byers
Contents
Preface iii
Contributors vii
1. Introduction: Tracing the Historical Development of Metalworking
Fluids 1
Jeanie S. McCoy
2. Metallurgy for the Nonmetallurgist with an Introduction to Surface
Measurement Finish
James E. Denton
61 Processes Cutting 3. Metal
Herman R. Leep
Performance of MetalworkinFg lu Gia dirn si ndinSg y stem
Cornelis Smits
135 Applications 5. Metalforming
Kevin H. Tucker
Che6m. isTtrhye o1f6 5M eF talulwidos r king
Jean C. Childers
VI
7. Laboratory Evaluation of Metalworking Fluids 191
Jerry P. Byers
8. Corrosion: Causes and Cures 223
Giles J. P. Becket
9. Metalworking Fluid Microbiology
L. A. Rossmoore and H. W. Rossmoore
10. Filtration Systems for Metalworking Fluids
Robert H. Brandt
11. Metalworking Fluid Management and Troubleshooting 305
Gregory J. Foltz
12. Recycling of Metalworking Fluids 339
Raymond M. Dick
13. Waste Treatment
Paul M. Sutton and Prakash N. Mishra
14. Contact Dermatitis and Metalworking Fluids 395
C. G. Toby Mathias
15. Healtha ndS afetyA spectsi n t he Use of MetalworkingF luids 411
P. J. Beattie and B. H. Strohm
16. GovernmRee ngtu latAiofn fesc Mtin egta lworkFilnu gid s 423
William E. Lucke
Glossary
Index 1
Contributors
P. J. Beattie Toxic Materials Control Activity, General Motors Corporation,
Detroit, Michigan
Giles J. P. Becket Products Division, Cincinnati Milacron, Cincinnati, Ohio
Robert H. Brandt Brandt & Associates, Inc., Pemberville, Ohio
Jerry P. Byers Product Research and Development, Products Division, Cin-
cinnati Milacron, Cincinnati, Ohio
Jean C. Childers Climax Metals Division, Sales and Marketing Department,
Amax, Inc., Summit, Illinois
James E. Denton Metallurgical Engineering Department, CumminsE ngine
Company, Inc., Columbus, Indiana
Raymond M. Dick Fluid Management Equipment, Products Division, Cincin-
nati Milacron, Cincinnati, Ohio
Gregory J. Foltz Customer Service, Products Division, Cincinnati Milacron,
Cincinnati, Ohio
Herman R. Leep Department of Industrial Engineering, University of Louis-
ville, Louisville, Kentucky
William E. Lucke Laboratory Services, Products Division, Cincinnati Milac-
ron , Cincinnati, Ohio
C. Toby Mathias Department of Dermatology, Group Health Associates,
Cincinnati, Ohio
Jeanie S. McCoy Cutting Fluid ManagementC onsultant, Jeanie McCoy Tech-
nologies, Inc., Lombard, Illinois
Prakash N. Mishra Technical Center, North American Operations, General
Motors Corporation, Warren, Michigan
H. W. Rossmoore Department of Biology, Wayne State University, Detroit,
Michigan
L. A. Rossmkre Biosan Laboratories, Inc., Ferndale, Michigan
Cornelis A. Smits Advanced Grinding Systems, Products Division, Cincinnati
Milacron, Cincinnati, Ohio
B. H. Strohm Toxic Materials Control Activity, General Motors Corporation,
Detroit, Michigan
Paul M. Sutton Environmental Engineering Consultant, P. M. Sutton &
Associates, Inc., Bethel, Connecticut
Kevin H. Tucker Technical Processesa ndE ngineering,P roductsD ivision,
Cincinnati Milacron, Cincinnati, Ohio
Introduction: Tracing the Historical
Development of Metalworking Fluids
McCoy
Metalworking fluids are best defined by what they do. Metalworking fluids are
engineering materials that optimize the metalworking process. Metalworking is
commonly seen as two basic processes, metal deformation and metal removal
or cutting. Comparatively recently, metal cutting has also been considered a
plastic deformation process-albeit on a submicrsoc ale and occumng just before
chip fracture.
In the manufacturing and engineering communities, metalworking fluids
used for metal removal are known as cutting and grindingf luids. Fluids used for
the drawing, rolling, and stamping processes of metal deformation are known
as metalforming fluids. However, the outcomeo f the two processesd iffers. The
processesb yw hich the machinesm ake the products, the mechanics of the
operations, and the requirements for the fluids used in each process ardei fferent.
The mechanics of metalworking governt he requirements demandedo f the
