1070 – 17 – Safety Precautions

Cutting fluid can be so expensive to dispose of because it’s highly regulated by the EPA due to its corrosive qualities and potentially deadly chemical make up. Some straight oil can be recycled, but getting rid of water-based fluids can be difficult. It needs extensive treatment before its ready to be disposed of, so be sure to speak with your local hazardous waste management organization.

It’s also a good idea to read your cutting fluid manufacturer’s safety data sheet. It will detail the risks of exposure – skin, eye, and stomach irritation – and the tests the manufacturer recommends, like concentration, pH, and bacteria tests.

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1070 – 01 – The Importance of Bandsaw Cutting Fluid in Metalwork

1070 – 01 – The Importance of Bandsaw Cutting Fluid in Metalwork

Why Bandsaw Cutting Fluid is Essential In the realm of metalwork, few things are as fundamental as a bandsaw and the right cutting fluid. Whether you’re cutting intricate designs or slicing through thick sheets, the success of your operation often hinges on the efficacy of your band saw cutting fluid. The Role of Cutting Fluid in Band Saw Operations Cutting fluid isn’t just an add-on; it’s essential to any band saw operation. The intense friction generated during cutting produces significant heat. Left unchecked, this heat can compromise the integrity of the blade, potentially damaging it or even warping your workpiece. […]

1070 – 02 – The Physics of Cutting Fluid Part 1

1070 – 02 – The Physics of Cutting Fluid Part 1

Understanding the forces at work when you’re cutting can help shed some light on why cutting fluid is key to making a successful, efficient cut. Cutting metal requires a lot of energy, and much of that energy is lost in the form of heat, which is caused by friction. When it comes to sawing, friction is caused by the blade grinding against the material. Here’s an example of friction in our every day environment: When you hit the breaks while driving, you’re able to stop because of the friction between your break pads and tires. Your wheels might even feel […]

1070 – 03 – The Physics of Cutting Fluid Part 2

1070 – 03 – The Physics of Cutting Fluid Part 2

Metal surfaces, which may seem smooth to the human eye, have microscopic lumps and ridges that can be extremely difficult to cut. Breaking through these features can kick up enough heat to melt through your workpiece. Furthermore, cutting fluid creates a film between the chip and band saw blade. This separates all the microscopic bumps in the surface and reduces friction. The components of cutting fluids, like chlorine and sulfur, also help lubricate the cut. They stand up well to the high temperatures involved in extreme metal sawing. There are several additional factors to take into account when it comes […]

1070 – 04 – What Happens to the Workpiece

1070 – 04 – What Happens to the Workpiece

The amount of heat created has a lot to do with the type of material you’re working with. Metals with low tensile strength, like brass or aluminum, create less heat. Steel and titanium, on the other hand, have high tensile strength, and therefore create more heat when they are cut. Besides tensile strength, the amount of heat generated also depends on how fast you’re cutting. Cutting at high speeds can cause temperatures to increase and pressures to create a built up edge (BUE). When a BUE forms, it becomes difficult to remove chips from the cutting area. That’s why the […]

1070 – 05 – Varieties of Cutting Fluid

1070 – 05 – Varieties of Cutting Fluid

Another essential factor to understand when it comes to cutting fluids is their chemical make up. There are two primary types of cutting fluids: oil-based fluids and water-based fluids. Oil fluids contain no water, while water-based fluids are usually a combination of water and lubricating chemicals. Each type can be ideal for a specific type of metal sawing. In addition to these types of fluids, some solids and greases can work well as coolers and lubricants. Some shops use gases, pastes, waxes, or soaps.

1070 – 06 – Oil Based Cutting Fluids Part 1

1070 – 06 – Oil Based Cutting Fluids Part 1

Oil-based fluids contain no water and are based on mineral oils. They can be divided into two distinct types: inactive straight oils and active straight oils. We’ll go over both varieties so you can determine which type will work best for your job. Active straight cutting oil is “sulfochlorinated”. Its chemical ingredients, which include sulfur and chlorine, make it ideal for jobs that require lubrication. Active oils can be sulfurized or sulfochlorinated Remember, though, that active straight cutting oil should not be used with brass, copper, or any of their alloys.

1070 – 07 – Oil Based Cutting Fluids Part 2

1070 – 07 – Oil Based Cutting Fluids Part 2

Inactive straight cutting oils are never mixed with water and are often composed of mineral oils, animal oil, or vegetable oil. Mineral cutting oils are ideal for light-duty sawing. Fatty oils are used in more taxing sawing operations and have either animal, vegetable, or marine oil added to their chemical make up. Inactive straight cutting oil would be ideal and can work for a range of jobs. When you use inactive straight cutting oil, be sure to remember that sulfur-based oils can cause erosion when used with steel, due to their corrosive qualities.

1070 – 08 – Water Based Cutting Fluids Part 1

1070 – 08 – Water Based Cutting Fluids Part 1

Water-based fluids are usually ninety to ninety-five percent water; the remaining concentration can be water-soluble oil, chemical-fluids, and semi-chemical fluids. Soluble oil cutting fluids are called “miscible fluids,” because they can be mixed with water. These types of cutting fluids contain emulsifiers, which are soap-like substances that enable the oil to mix appropriately with the water. Composed of 60-90% oil, the remaining water content means that these fluids cool better than straight oils. It’s key to point out that super-fatty soluble oils have animal or mineral oil in their chemical make up. It makes them ideal for use when cutting […]

1070 – 09 – Water Based Cutting Fluids Part 2

1070 – 09 – Water Based Cutting Fluids Part 2

Chemical fluids fulfill a variety of purposes: They have nitrates that prevent rust, phosphates that soften water, defoamers to reduce foaming, soaps that offer lubrication, pressure additives that also assist with lubrication, and biocides that stop bacteria growth. Chemical fluids do an excellent job of cooling cutting surfaces. One major benefit of using chemical fluids is their resistance to dissolving tramp oil, which makes it easy to skim the tramp oil off.

1070 – 10 – Oil Based Cutting Fluids Part 3

1070 – 10 – Oil Based Cutting Fluids Part 3

Semi-chemical fluids have different levels of soluble oils and chemicals. These mixtures are fine-tuned to the type of metals the fluid will be used to cut and the type of cutting operation in which it will be used. There are three main types of semi-chemical fluids: plain fluids, which have no added fat, super-fatted fluids, which have animal fat or vegetable oil added, or extreme pressure fluid, which contains chlorine and sulfur to add to the fluid’s lubricating qualities. Semi-chemical fluids are ideal for jobs that require either cooling or lubricating. They work particularly well with non-ferrous metals and, in […]

1070 – 11 – Choosing The Right Cutting Fluid

1070 – 11 – Choosing The Right Cutting Fluid

With so many choices out there, how do you choose the best cutting liquid for your operation? Manufacturers of cutting fluid often have well-tested tables from manufactures detailing the best way to select the right cutting fluid. These labels are generally reliable and provide the most appropriate fluid based on the type of operation it will be used for and the metal it will help to cut. When you’re reading one of the manufacturer’s tables, first locate the type of material you’ll be using. Then, find the cutting operation you plan to conduct, and the table will offer a choice […]

1070 – 12 – Ways to Work with Cutting Fluids

1070 – 12 – Ways to Work with Cutting Fluids

There are a variety of ways to work with cutting fluids. These include:The Flood Method, which is the most common because it completely covers the tool and workpiece. Or the ring-distributor method, which feeds into a small tube with many holes, directing fluid around the perimeter of the cutting tool. Another way of delivering cutting fluid is the high-pressure method. Central systems can be appropriate for certain types of semi-chemical cutting fluids because the oil can easily be removed from the fluid as it becomes corrupted by use.

1070 – 13 – Getting the Most Out of Your Cutting Fluid Part 1

1070 – 13 – Getting the Most Out of Your Cutting Fluid Part 1

One of the added benefits of cutting fluids is their longevity. Many types of cutting fluid can be continuously reused. As a rule, oils stand up to the wear and tear of machining better than water-soluble cutting fluids. Just be sure that the tramp-oil from the machine itself does not contaminate the cutting fluid. Choosing the right lubricant also depends on the oil’s viscosity, which will provide lubrication. It’s also important to check the acidity of the oil; highly acid oil may mean that the cutting fluid has gone rancid.

1070 – 14 – Getting the Most Out of Your Cutting Fluid Part 2

1070 – 14 – Getting the Most Out of Your Cutting Fluid Part 2

Inspecting the oil is also an important step in the cutting process. Viscosity, for example, tells scientists how well the cutting fluid will function as lubrication. Like oil-based fluids, water-based fluids have a specific set of conditions under which they operate best. Be sure to find out whether the water you’re using is hard or soft. Water hardness is caused by the presence of calcium and magnesium in the water, which can damage both cutting blade and work piece. Medium-soft water is ideal for almost all Sawblade.com metal cutting operations.

1070 – 15 – Testing Your Cutting Fluid and Water

1070 – 15 – Testing Your Cutting Fluid and Water

Another crucial measurement to take is the pH with a pH meter or test strips. If the pH is between 8.7 and 9.2, it falls within acceptable standards. Any higher and the fluid can cause skin irritation, while a lower pH can cause a foul odor. Besides cutting fluid’s pH and water hardness, fluid concentration is also an important factor to take into account. If the fluid is too concentrated, it can lead to excessive foaming, which prevents the coolant from functioning effectively. If the fluid is not concentrated enough, it can cause parts to rust. Use a refractomoter to […]

1070 – 16 – Responsible Disposal Methods

1070 – 16 – Responsible Disposal Methods

Now that you know how to use cutting fluids, how do you clean and dispose of them responsibly? The cleaner a cutting fluid is, the more effectively it works. There are a number of ways you can clean cutting fluid: First, you could allow the debris to drift down to the bottom of the machine sump, where you can scoop it out after the system is drained. Second, you can skim the tramp oil out with a skimmer, which transfers tramp oil into a disposal container. Filtration is another way to clean your cutting fluid. Most shops use a vacuum […]

1070 – 18 – Why Cutting Fluid is Essential?

1070 – 18 – Why Cutting Fluid is Essential?

Cutting fluid is meant to be a boost to your tools cutting capacity, enhancing your shop’s cutting capabilities and ensuring that you get the best results for your effort. It’s cooling and lubricating qualities make it essential to many different types of sawing operations. Different types of cutting fluids, oil-based or water-based, have distinct features that lend themselves to low or high tensile cutting operations. Be sure to choose the most appropriate type of cutting fluid for your job at hand, always consulting with the manufacture’s recommendations for use, safety, and disposal.

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