The foam problem of semi-synthetic metal cutting fluid should be solved in this way!

November 23, 2023

The foam problem of semi-synthetic metal cutting fluid should be solved in this way!

With the advent of the Industry 4.0 era, metal processing enterprises pay more attention to improving the performance and adaptability of machine tools to achieve cost reduction and efficiency. Therefore, the application of semi-synthetic cutting fluid containing oil is becoming more and more extensive. Although semi-synthetic metal cutting fluid can improve processing efficiency, the foam problem has been plaguing all aspects of metal processing, and solving the foam problem is also a job that occupies a large chunk of time for technical research and development and technical service personnel. Based on the current system of semi-synthetic metalworking liquids, everyone is looking for the right way to mitigate the effects of foam. Next, we will summarize the foam phenomena encountered in the work and the possible causes from the perspective of the formulation, chemical selection, machinery and application of metal working fluids.

From the formula of metal cutting fluid

Fully synthetic product

Under normal circumstances, all synthetic products are oil-free formulation system, almost no emulsifier is added, and special water-based polyethers are used, so air release and foam performance are good, and foam problems are rare.

When there are foam problems, most of them are related to field applications, and the root cause needs to consult our technical service engineers.

Semi-synthetic product

Now the semi-synthetic product market is the most widely used, the design and processing field is the most, the foam problem still needs to be designed according to the application, not only a product can cover any application.

Semi-synthetic products to shoulder cooling, lubrication, cleaning, metal protection and other multi-faceted functions, but also to meet the customer's environmental protection, friendly operation, low consumption and long life requirements. In order to meet the needs of customers, we need to consider the balance between the various performance of the product when designing the formula, and meet the needs of most customers as much as possible.

Generally, the defoaming of semi-synthetic cutting fluid depends on the hardness of defoaming agent and water (calcium and magnesium ions in water), and traditional defoaming agents are time-sensitive, so the hardness of water plays a decisive role in the foam performance.

For customers with hard water quality

The requirement of hard water resistance of cutting fluid is very high, but the problem of foam is rarely worried;

For customers using soft water

The requirements for hard water resistance of cutting fluid are low, and there may be concerns about foam problems.

Therefore, how to choose products or design products according to the customer's working conditions and water quality is a very important step, so according to the process status, recommend the right products can solve the customer's foam problem.

In addition, some special application conditions on the foam requirements are also extremely strict, such as: 70Bar high pressure processing, traditional product foam is difficult to meet. Therefore, for the high injection pressure metalworking conditions, the corresponding formulation platform is needed to solve the application to meet the demand for foam.

From the formula of metal cutting fluid

In most cases, once there is a foam problem, there may be customers complaining that the product is not foam, and it is easy to label the product as "poor foam". In the foam performance, we need to be rational, in addition to ensuring the foam performance of the cutting fluid itself, but also need to supplement from other aspects.

We can try to consider the performance and control of metal cutting fluid during operation from the perspective of "people, machines, materials, methods, and rings".

The following are common factors that cause foam problems:

Site management reasons

Fluid rehydration is irregular and without procedures

The planned regular supplement of concentrated liquid can establish a relatively stable balance of the cutting fluid itself, and the consumed components are replenished in time. Avoid the unplanned operation and maintenance of "three days fishing, two days drying the net".

Single-machine rehydration, only add water, do not fill concentrated liquid, we recommend that when rehydration, if the water volatilization concentration is high, it is recommended to add a low concentration of cutting fluid, can not only add water.

The concentration of liquid in use is too high

Generally, the higher the concentration, the worse the foam trend, so it is recommended that the concentration be controlled within our recommended application range.

The hardness of the liquid in use is low

Under normal circumstances, the cutting fluid to maintain a certain hardness is helpful to the improvement of the foam, the hardness of the liquid is too low, the need to appropriately add some hardness enhancer to reduce the foam.

The liquid in use is contaminated

Avoid the entry of chemicals other than cutting fluid, such as cleaning agents (except for the design of compatible cleaning agents), last time processing fluid residue, washing products (equipment scrubbing), or other brands of cutting fluid.

Equipment problem on site

Tank design or volume problem

Especially for the centralized liquid supply with upper discharge and upper control, if the liquid return tank is designed too small, the foam can not be static and eliminated, there is often a risk of foam benefits, so this problem needs to be considered when designing the liquid tank.

Tank cleaning problem

For many single-machine bottom collection tank, if there is no filter, the bottom of the box is very easy to gather a large number of metal chips, occupy the liquid tank volume, a little foam will be beneficial, so it is recommended to clean the liquid tank regularly.

Pump empty problem

This problem is relatively rare, and once the pump is empty, the foam is pumped into the pump for multiple cycles, and the foam is serious.

High liquid temperature

The temperature of the cutting fluid is usually controlled at 20-30 ° C, and the high temperature also has a negative effect on the foam, and the cooling system needs to be regularly tested.

Injection pressure

Generally, the injection pressure recommended for cutting fluid applications is about 3-30Bar, if the injection pressure is too high, please consult our engineers before use.

The use of defoamer

The use of defoaming agents often needs to be combined with the working conditions of the site, the limitations of the factory and the cutting fluid products to select the most appropriate defoaming additives.

As an "important member" of metal processing, cutting fluid is very important. At the same time that cutting fluid production enterprises innovate and upgrade products, metal processing enterprises should also ensure the full realization of cutting fluid efficiency, so as to save equipment energy consumption, extend equipment life, improve energy efficiency, and help enterprises successfully enter the era of Industry 4.0.

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