Keeping the wheels of industry moving

The UK industrial and manufacturing sectors have experienced dramatic changes in recent years due to the demand for higher quality and increased productivity. In resolving these often conflicting issues, suppliers to both key sectors need to continuously provide innovative solutions to keep the wheels of industry moving – and nowhere is this more important than in the UK’s metalworking environments. 

These vital industrial and manufacturing suppliers serving industries such as automotive, aerospace, agriculture and construction – rely heavily on industrial lubrication specialists to keep a wide variety of sophisticated metalworking and metal forming machines working effectively and efficiently. 

Soluble metalworking fluids are available in three main types: synthetic, semi-synthetic and mineral-based. Products are blended with specialist additives and the combination determines the type, quality and performance properties of the finished lubricant. As machine tools and machining operations become more sophisticated, highly effective tool lubrication is vital and recent developments in metalworking technology have led to the introduction of new high performance fluids. 

Workshop managers are aware that carefully matching materials, machining operations and metalworking fluids can make a measurable difference to their operation, helping them to exploit and optimise a plant’s potential by increasing machining capacity and maintaining the quality of the components produced. 

In practice, metalworking fluid specification can depend on factors such as component complexity, material quality, severity of the operation, and machine speed, and can involve selecting from thousands of products. Options range from multi-purpose fluids for general machining on a wide range of materials, to synthetically enhanced, ‘Ultimate Performance’ fluids, designed to excel in arduous operations where conventional fluids will fail.

While the cost of metalworking fluids is a small proportion of the total machining cost, products, developed using the latest technologies can contribute towards further savings by extending tool life, enhancing the performance of the machine tool and reducing disposal costs through extending the sump life of the fluid. 

Fluids developed with these new technologies can be selected to deliver specific characteristics. For example a semi-synthetic, water mix fluid can be formulated to machine ferrous and non-ferrous materials in soft and hard water areas. This can be enhanced to provide increased bio-stability, high fluid stability and cleanliness resulting in little or no maintenance, even when machining traditionally dirty materials such as cast iron, black bar and flame cut steel. Other formulations can incorporate synthetic lubricity and extreme pressure additives designed to extend tool life while delivering an excellent surface finish with outstanding corrosion protection.

There are also advancements in neat metalworking fluids and for the most demanding metalworking operations, fluids based on the high quality, hydro-finished base oils are available. These are subjected to a special process that removes any remaining impurities, rendering them clear, pure and results in high oxidation stability. This ensures that fluids maintain colour, viscosity and, most importantly, product integrity in order to prolong fluid life. Such products also improve health and safety in the workshop by minimising the amount of oil mist released into the working environment.

A number of lower viscosity neat metalworking fluids have also been developed for low, medium and severe duty machining operations on materials including Aluminium Alloys, Stainless Steels and Titanium Alloys. The low viscosity is proving particularly beneficial for use in through-tool lubricant applications.

Today, metalworking fluid suppliers have specialist chemists and technical help lines to assist with product recommendations. They will provide OEM approvals, product information, health and safety data, problem solving advice and trouble shooting. Also available are highly specialised after sales packages such as used oil test analysis that can give diagnostic advice and support if required. Where necessary, laboratory analysis is available to support problem solving, backed up by technical reports detailing recommendations and corrective action.

In summary, today’s neat and soluble metalworking fluids have been specifically engineered to meet the stringent demands of modern component manufacturers and the extensive and more exotic range of materials they now machine. As technology requirements advance, lubricant specialists will be required to continue to push boundaries and develop products that ensure their customers achieve optimum performance and value for money.