90% Of Machining Masters Mix The Wrong Cutting Fluid! If The Order Of Adding Water Is Wrong, The Anti-rust Lubrication Will Be Scrapped Directly.

90% of machining masters mix the wrong cutting fluid! If the order of adding water is wrong, the anti-rust lubrication will be scrapped directly.

You can only add oil to water, never water to add oil.

In order to save trouble, many workshop workers first pour the cutting fluid solution into the bucket, and then add water into it. This action is the most common cause of factory problems. The correct approach is: first place water in the bucket, and then slowly pour in the original cutting fluid solution. If the operation is reversed, the emulsification system of the cutting fluid will be destroyed, causing the liquid to stratify rapidly.

In a real-life example, there is a machinery factory in Shandong. Its workers usually pour the original solution first and then add water. As a result, on the third day, the cutting fluid smells bad and becomes rusty. The emulsifier in the original solution cannot spread evenly when it comes into contact with water, and the lubrication and anti-rust properties are directly reduced. Rust spots quickly appear on the machine tool guide rails and the surface of the workpiece, and the tool wear rate doubles.

If the mixing method is not correct, the liquid will be ineffective.

When feeding, the stirring state needs to be maintained during the entire process. However, this stirring must be done by turning up and down, and must not be carried out in a circular rotation type stirring operation. When adding the original solution to the water, add it slowly and in small amounts multiple times, and keep it at a low speed and mix evenly. If violent and high-speed stirring is carried out, a large amount of foam will emerge from the liquid, which will destroy the stable structure.

There was a situation where a high-speed mixer was used to mix liquid in a precision machining workshop in Changzhou. However, foam overflowed the water tank and the cooling effect deteriorated. The resulting problem is that the machining accuracy is affected and scratches appear on the surface of the workpiece. Later, technicians adjusted the mixing method, so the foam problem disappeared and the stability of the liquid was significantly improved.

Hard water is an invisible trap

Water with a high content of calcium and magnesium ions is classified as hard water. The inorganic salts present in it will react with the cutting fluid emulsifier to generate white scum. The active ingredients of the cutting fluid are thus decomposed, and its ability to lubricate and prevent rust will rapidly decay. On the market, 70% of processing plants ignore water quality testing, ultimately causing the cutting fluid to be scrapped early.

The optimization standards are as follows: pure water used for a long time after softening has the highest stability, and the cutting fluid is not prone to deterioration; medium hardness water can be compatible with conventional water-soluble cutting fluids; water with high hardness must be softened in advance. The simple processing method is to add 100 grams of anhydrous sodium carbonate or 300 grams of soda decahydrate for every kilogram of water, stir it and let it sit for an hour, and select the upper layer of water for mixing. From a long-term perspective it is recommended to install professional water softening equipment.

Complete standard mixing steps

The first step is to calculate the demand for clean water and cutting fluid based on the capacity of the machine tool water tank. In the second step, the water tank or mixing barrel must be filled with clean water first. If it is hard water, it must be softened in advance and left to stand. In the final third step, stir the water up and down at a low speed, and then slowly pour the cutting fluid stock solution in portions.

Step 4: After all the additions are completed, continue stirring for a few minutes. When the liquid is uniform and has no stratification, it can be used on the machine. After a CNC processing plant in Guangdong followed this process, the service life of the cutting fluid was extended from 15 days to 45 days, and the rust rate of the workpiece was reduced by 80%.

The real losses caused by improper proportioning operation

The workpieces were processed after the emulsification failed, and rust soon occurred, resulting in batches of defective products. Due to insufficient lubrication of the cutting tools, the wear is aggravated, and frequent replacement of cutting tools increases the cost of consumables. The liquid is prone to foaming and smelly, and the entire box needs to be replaced, resulting in serious waste of raw materials.

An auto parts manufacturing factory in Anhui scrapped more than 300 workpieces within a month due to incorrect ratios, resulting in direct losses of more than 50,000 yuan. The metal parts and water tank of the machine tool were corroded to a certain extent, which resulted in an additional maintenance cost of more than 20,000 yuan. The losses caused by these can actually be avoided by standard operation.

Recommended by reliable cutting fluid manufacturers

Yantai Hengxin Chemical, which has been deeply involved in the field of metal processing chemicals for 25 years, specializes in the research and development of a full range of water-soluble cutting fluids, specializes in the research and development of semi-synthetic cutting fluids, specializes in the research and development of aluminum alloy special cutting fluids, and specializes in the research and development of grinding fluids. Its products have balanced lubrication performance, balanced cooling performance, and balanced anti-rust performance. They can adapt to various working conditions of lathes, can adapt to various working conditions of grinders, and can adapt to various working conditions of CNC machining centers.

They provide free technical support and on-site guidance to help companies optimize the ratio plan. If you choose an experienced supplier for the cutting fluid selection guide for metal parts processing , you can reduce errors in proportioning operations at the source, thereby reducing the overall cost of use.

In your workshop, have you ever encountered the situation where the cutting fluid stinks, or the cutting fluid produces rust? You are welcome to share relevant experiences in the comment area, and help more industry partners avoid such troubles by liking and forwarding!