Water Cutting Fluid Vs. Neat Cutting Oil: Choosing The Right Solution For Metal Machining
Certainly, deciding whether to use water-based cutting fluid or neat cutting oil in machining depends on several factors. The most important requirements to be met by coolants in metal cutting are reduction of tool wear, a high-quality surface finish and economy of use. This guide explores the key differences between these two options, helping you make an informed decision for your machining processes.
Neat Cutting Oil
As we know, water-soluble cutting fluids and neat cutting oils are used in metalworking operations. Still, they differ in their chemical composition, application and cost. The most important requirements to be met by coolants in metal cutting are reduction of tool wear, a high-quality surface finish and economy of use. We will explain the difference between water-soluble cutting fluids and neat cutting oils by comparing the two products' characteristics and application as below.
Neat cutting oils blend mineral oils and other additives and are used for cutting without further dilution. And, water-based cutting fluids need to mix with water that usually forms a milky and emulsion to processing.
Water-dilutable Cutting Fluid
Water-dilutable cutting fluids are also referred to as coolant, water-based cutting oil, and cutting fluid. As we know, water-dilutable coolants have a good cooling performance to maintain the cutting temperature within the limit, and are easy to clean during machining. However, there are many uncertain factors that cause pH scale and concentration spoilage.
Therefore, coolant maintenance will be an important thing for operators. Water-dilutable cutting fluids are generally grouped into three major categories: soluble cutting oils, semi-synthetic cutting oils, and synthetic cutting fluids (grinding fluids). Generally, three types of water-dilutable cutting fluid:
■ Soluble Cutting Fluid
Soluble cutting fluids are coarse insoluble phase mixtures forming oil-in-water emulsions. The emulsions are mixtures of base oil, emulsifiers, anti-wear, extreme pressure, anti-foaming additives, corrosion inhibitors, bactericides, etc. Medium viscosity petroleum-based or mixed-type mineral oils are usually used as mineral bases; their content in the emulsion can be up to 85%.
■ Semi-synthetic Cutting Fluid
Semi-synthetic coolants are metalworking fluid concentrates that contain a small amount of oil as well as synthetic lubricants and other additives. When mixed with water, they form a translucent fluid. Semi-synthetics combine the physical lubricity of soluble oils with the chemical lubricity, cooling, and cleanliness of synthetic coolants. They have a higher content of emulsifiers (up to 40%) and always contain low-viscosity (3-10 mm2/s at 50°C) mineral or synthetic oils, as well as extreme pressure, anti-wear and other additives.
■ Synthetic Cutting Fluid
Synthetic cutting fluids are mixtures of water-soluble organic products with molecular dispersion. They do not contain mineral oil base or petroleum which is form a clear fluid when mixed with water. Instead, they're formulated from alkaline organic and inorganic compounds alongside additives to prevent corrosion. They function well in their diluted form. All of the varieties of cutting fluids, synthetic fluids offer the best cooling performance.
Neat Cutting Oil
Neat cutting oils, also referred to as straight oils, are mineral-based lubricants used for metal machining. On the other side, neat cutting oils have excellent lubricating for light to heavy machining (such as broaching, turning, honing and drilling, etc.) which is based on mineral oils and used for cutting without further dilution.
Neat cutting oils, also referred to as straight oils, are mineral-based lubricants used for metal machining. On the other side, neat cutting oils have excellent lubricating for light to heavy machining (such as broaching, turning, honing and drilling, etc.) which is based on mineral oils and used for cutting without further dilution.They are generally blends of mineral oils and other additives. But neat cutting oils will produce oil mist and oil smoke while metalworking causes misting and slippery conditions throughout the workplace. If environmental considerations are paramount, water-based cutting fluids are a more sustainable choice due to their lower environmental impact. Neat cutting oils can produce mists that pose health risks to operators. Water-based fluids are generally safer in this regard. Choosing between water-based cutting fluids and neat cutting oils depends on your machining goals, materials, and environmental concerns. Both options offer distinct advantages, so a careful evaluation of your specific machining needs will guide you toward the solution that maximizes efficiency, tool life, and product quality.
Comparison Chart
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