NEWS
In modern machining workshop, the selection of guide rail oil is very important. Guide rail oil can affect the accuracy of machining and the service life of metalworking fluid, and then directly affect the production efficiency of machine tools. Ideal guide rail oil not only needs excellent friction control, but also has excellent separability with water-soluble cutting fluids commonly used in metal processing. If the selected guide rail oil cannot be completely separated from the cutting fluid, the guide rail oil will be emulsified, or the performance of the cutting fluid will become worse, which are the two major inducements leading to the corrosion of the guide rail of modern machine tools and the poor lubrication effect of the guide rail. For machining, when guide rail oil meets cutting fluid, there is only one mission to let them "leave"!
Therefore, when selecting guide rail oil and cutting fluid, enterprises should effectively evaluate and test their separability to avoid losses in the actual processing process. When choosing the best combination of guide oil and cutting fluid, how to evaluate and measure their separability undoubtedly plays an important role.
The following six simple and practical methods can help solve the separation problem of guide oil and cutting fluid easily:
One move to see through: symptoms caused by poor separation performance
The guide rail lubrication is usually in the fully open state, which often pollutes the cutting fluid. Therefore, as one of the most important properties of the guide rail oil, it must be well separated from the water-soluble cutting fluid, rather than miscible. Good separation can not only help to avoid higher production costs, but also effectively reduce the occurrence of unexpected downtime due to equipment failure.
If the separation between the guide oil and the cutting fluid is not good, the guide oil will emulsify and cause the following problems:
a. Reduced lubrication and increased friction
b. May lead to higher energy consumption
c. Wear of material surface or coating material in contact with guide rail
d. Corrosion of machine and parts
Poor separation will also make the guide rail oil emulsified in the water-soluble cutting fluid, resulting in:
The cutting fluid concentration changes and the performance becomes difficult to control
Poor lubrication effect, serious tool wear and poor machined surface quality
Increased risk of bacterial reproduction and odor generation
Reducing the pH value of cutting fluid may cause corrosion
Too much foam in cutting fluid
Two methods Test: quickly identify the separability of guide rail oil and cutting fluid
The treatment cost of cutting fluid contaminated by lubricating oil is very high. Therefore, it is better to nip in the bud than to make amends after symptoms occur. Machining enterprises only need to pass
Two simple standard tests can quickly judge the separability of the guide oil and cutting fluid to be selected.
Toyoda anti emulsification test
Toyoda test simulates the phenomenon that guide rail oil contaminates cutting fluid. In the test, inject 90ml cutting fluid and 10ml guide oil into the container, stir them vertically for 15 seconds, and then observe the condition of the liquid in the container at 16 hours, and measure the solvent (in ML) of the liquid at the top, middle and bottom of the container: the separated guide oil (top), "emulsion") and water (middle) and the separated cutting fluid (bottom).
If the recorded test result is 90/0/10 (90ml cutting fluid, 0ml lotion, 10ml guide rail oil), it indicates that the oil and cutting fluid are "completely separated"; If the result is 98/2/0 (98 ml cutting fluid, 2 ml lotion, 0 ml guide rail oil), it means that the emulsification reaction occurs, and the cutting fluid and guide rail oil are not well separated.
Separability test of FKT metal cutting fluid
This experiment simulates the contamination of guide rail oil by water-soluble cutting fluid. Mix the guide rail oil with various conventional cutting fluids in the ratio of 80/20, including 8ml of guide rail oil and 2ml of cutting oil. The mixture was stirred at 1500rpm for 1 minute, and then the state of the mixture was visually observed after 1 hour, 1 day and 7 days. The state of the mixture is scored on a scale of 1-6 according to the following criteria:
1= completely separated
2= partial separation
3= oil + Intermediate
4= oil + intermediate + emulsion
5= intermediate + emulsion
6= all intermediates
Experiments show that using cutting fluid and guide rail lubricant from the same supplier can help to achieve better separation between the two.
Three measures for maintenance: the key to ensure the efficient operation of the production workshop
Of course, the determination of the separation of guide oil and cutting fluid does not mean once and for all. During the operation of the equipment, there are still many uncontrollable factors that affect the performance of guide rail oil and cutting fluid, which can not be ignored. Daily maintenance is also one of the key factors to ensure the efficient operation of the workshop.
·Good maintenance: besides guide rail oil, other machine tool lubricating oils, such as hydraulic oil and gear oil, will also cause pollution. Therefore, regular maintenance is essential to prevent the pollution caused by cutting fluid contacting different machine tool oils, prevent anaerobic bacteria from proliferating in the cutting fluid, and then maintain the good performance of the cutting fluid, prolong its service life and reduce the generation of odor.
·Cutting fluid performance monitoring: use a refractometer to regularly monitor the concentration of cutting fluid. Under normal circumstances, a bright thin line will appear on the refractometer. However, if the cutting fluid contains more emulsified guide oil, the thin lines on the refractometer will become blurred, which means that the content of floating oil is relatively high. Alternatively, the concentration of cutting fluid can be measured by titration, and then the result can be compared with the concentration of fresh cutting fluid to obtain the degree of oil slick emulsification.
·Removing oil slick: many modern machine tools have been equipped with automatic oil slick separators, or the equipment can be equipped with separate oil slick separators. In large systems, filters and centrifuges are generally used to remove oil slicks and other pollutants. In addition, tools such as industrial vacuum cleaners can be used to remove the oil slick manually.
