Due to the certain limitations of the aqueous cutting fluid itself, many problems arise when used. There are many objective factors in the generation of these problems, including temperature difference, water quality, raw material quality, working conditions, and operator habits. For some problems, provide some solutions and solutions for your reference.
First, how to deal with the problem of cutting fluid injury
The characteristics of the cutting fluid injury are: hand peeling, skin rash, blistering, inflammation, itching, ulceration, etc., to solve these needs to understand the various components of the cutting fluid.
1. For the case of hand peeling, there is a great relationship with the pH value of the cutting fluid. If it is too high, this feature will occur. Generally, the working fluid of the cutting fluid of cast iron and steel is kept as high as 8.5-9.5. For the aluminum working fluid, the pH value should be kept between 8.5-9.0. Such as reducing the amount of triethanolamine used.
2. Other symptoms of the skin on the hands. It is related to the fungicide in the cutting fluid. If the amount of the fungicide is too high, it will irritate the skin and cause inflammation. The mechanism of the action of the triazine-based fungicide such as (BK) is the decomposition of the fungicide by the bacteria to produce formaldehyde, and the formaldehyde has the effect of antiseptic sterilization. . Formaldehyde can irritate the skin and cause inflammation, so the use of such fungicides should not be too high, and excessive use of sodium nitrite can also irritate the skin, causing itching and ulceration.
In addition, other reasons, such as the operator's physical condition, skin allergies and other factors, are not excluded.
2. There is no rust on the cast iron and steel parts processed, and the machine guide rails are rusted.
Some load processing requires the addition of extreme pressure agents (mainly compounds containing extreme pressure active elements such as S, P, Cl). The combination of these additives and lubricants can greatly improve the difficulty of cutting and improve the wear resistance of the tool. ability. The disadvantage is that the addition of these materials to water-soluble cutting fluids can easily corrode many metals. When these compounds are dissolved in water, a small amount of free CL, S, and P are combined with hydrogen ions in the water to produce an acid which corrodes the guide rail.
For the domestic production of S52, it is best to add some oleic acid to neutralize the free elements to achieve corrosion resistance.
Third, the rust of the workpiece appearing in the summer of the fully synthetic cutting fluid
Because the fully synthetic cutting fluid does not contain oil, many manufacturers will choose inorganic salts as their anti-rust additives, such as sodium nitrite, boric acid, sodium benzoate, sodium gluconate, sodium carbonate, etc. The anti-rust properties of sodium molybdate are very good. However, the price is too expensive, the addition amount of other inorganic salts is generally high to achieve a good rust-proof effect, the summer weather is hot, the water evaporation is large, and the operator does not add the cutting fluid in time, resulting in the inside of the liquid tank. When the inorganic salt reaches a saturated state, it precipitates and adheres to the surface of the workpiece, which not only prevents the rust from reaching, but also causes great trouble to the subsequent cleaning.
Therefore, the amount of inorganic salt added is appropriately reduced, and the addition of an organic rust inhibitor can improve this, such as boric acid ester, amino acid ester, carboxylic acid, etc., and the rust prevention is good, and the system is more stable.
Fourth, the problem of the use of cutting fluid in the refractometer and acidity meter
The refractometer has become an instrument for measuring the active component of the cutting fluid. It has the advantages of convenient detection and fast reading. The mechanism of action is to use light to test the liquid concentration. The value measured for the new liquid (the cutting fluid just after water) is the most accurate, and the factory inspection of the general cutting fluid is done through it. The detection value of the cutting fluid used for a period of time on the machine tool is not so accurate. At this time, the detected value can only be used as a reference, and cannot be used as a basis for judging whether the cutting fluid has no problem. In most machine tools, mechanical oil such as hydraulic oil and guide oil may leak into the cutting fluid. At this time, the value detected by the refractometer is too high, and there is a gap between the actual value. At this time, the inspection personnel need to be based on experience and on-site work. To determine the seriousness of the problem, make appropriate recommendations, such as adding fresh cutting fluid to the cleaning tank.
The acidity meter is the main instrument for detecting the cutting fluid. The discharge of the cutting fluid is detected by the discharge of the electrode. When the pH value is converted into a pH value, as long as the value of the periodic detection does not change greatly, the cutting fluid will not remain in the proper range. There are big problems.
5. Regarding the “burn†generated during grinding, it is not enough cooling or lubrication.
Problems such as burn blue and blue during grinding are caused by local high temperature during grinding. Grinding is a high-speed cutting process, and an instantaneous high temperature is generated at the grinding point. Therefore, the burn problem occurs during the grinding process. The role of the grinding fluid is to take away the accumulated heat on the grinding wheel and the workpiece in time to keep it at a lower temperature level to ensure the dimensional accuracy of the workpiece. The lower temperature level of the grinding wheel and the workpiece is of course effective in reducing the temperature in the grinding zone, but this cooling is indirect. The most straightforward way is to improve the lubrication conditions in the grinding zone and to reduce the instantaneous high temperature of the friction points. Therefore, if the burn problem occurs, it is mainly solved by improving the lubricity of the grinding fluid.
Sixth, the problem of blackening and mildew on the surface of the workpiece when processing aluminum parts
　　 》》》Selection of cutting fluids for aluminum and aluminum alloy processing
Since the chemical properties of aluminum are relatively active, it is easy to chemically react with acids and bases to cause corrosion, rust, blackening and mildew. The first consideration when dealing with such problems is that the pH of the cutting fluid cannot be too high and is maintained between 8.5 and 9.0 . The rust preventive used should have the stability of corrosion inhibition and pH maintenance . It is best to use rust inhibitors such as phosphate ester and sodium silicate which can form a protective film on the surface of the workpiece. Minimize the use of inorganic salt rust inhibitors, and the amount of inorganic salts used is not high. For the processed aluminum parts, it is necessary to clean them in time, and then apply anti-rust oil to prevent rust (or passivation).
7. The reason why a lot of foam appears when the cutting fluid is used.
The components of the cutting fluid contain a lot of surfactants, commonly known as cleaning agents, such as TX-4, flattening, 6501, 6503, etc. These cleaning agents produce a large amount of foam when used, which is disadvantageous for machining. It will pollute the processing environment and cause inconvenience to the production personnel. Leaking out of the machine tool will also reduce the cleaning ability of the cutting fluid. At this time, it is possible to remedy by adding a small amount of an antifoaming agent (the silicone oil is the fastest, the polyether is strong, and the foam can be suppressed). In addition, the cutting fluid needs to increase the content of the defoaming agent in the mother liquor in the summer, and this is also related to the liquid level of the machine tool tank and the sealing performance of the circulating pump. Appropriate increase in the amount of defoamer can be solved for these conditions.
Eight, the problem of odor when using cutting fluid
The cutting fluid is divided into emulsified oil (emulsion), semi-synthetic (microemulsion), and total synthesis. Because the emulsified oil contains a lot of mineral oil, it provides a hotbed for bacteria, fungi and mold. If no bactericide is added, the bacteria will grow a lot in a short period of time, and the odor will occur. The use of an unsuitable bactericide will not solve the problem.
At present, fungicides are classified into triazines (BK), morpholine derivatives (MBM), sodium pyrithione, benzisothiazolinones, polychlorophenols, etc., and BK and MBM are commonly used . BK formaldehyde release type is effective for bacteria, fungi and mold are generally effective, and it is suitable for use in semi-synthesis and total synthesis, and precipitation and stratification may occur in emulsified oil. In addition, there is no bacteria in the liquid tank of the machine tool, so formaldehyde will not be produced, and it will not have the effect of sterilization and sterilization. MBM morpholine is effective for bacteria, fungi, and mold, and is suitable for use in a processing fluid having a high oil content such as emulsified oil.
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