Metal working fluids (MWFs) provide important functions such as lubrication and cooling in the machining of metals. This book reviews the issues surrounding the use of fluids for cutting and grinding throughout the metal working process, from selection and testing to disposal. The book opens with chapters considering the mechanism and action, selection and delivery of MWFs to the machining zone before moving onto discuss the many issues surrounding MWFs during machining such as selection of the proper MWF, environmental concerns, supply methods, circulation and monitoring. The final chapters discuss the maintenance, replacement and disposal of MWFs. With its distinguished editors and international team of expert contributors, Metalworking fluids (MWFs) for cutting and grinding is an invaluable reference tool for engineers and organizations using metal cutting/machining in the manufacturing process as well as machine designers/manufacturers and machining fluid/chemical suppliers. Chapters consider the mechanism and action, selection and delivery of MWFs to the machining zone Environmental concerns, supply methods, circulation and monitoring are also discussed Written by distinguished editors and international team of expert contributors

"Cutting and grinding fluids at one time were considered little more than a necessary nuisance. However, they are something the metal working industry cannot do without. Today, thousands of blends of fluids provide the necessary lubricity and cooling to allow heavier feeds, higher speeds, and longer tool life demanded in the modern machining industry. Metal working fluids today need not be a nuisance if properly selected, applied, and maintained. This book provides comprehensive information on how to successfully select, apply and maintain cutting and grinding fluids for maximum productivity, minimum waste, and safe performance."--Back cover.

This work provides concise introductory material on metallurgy for the novice, presenting up-to-date information on metalworking fluid technology. Its history, formulation, application, maintenance, testing and governmental regulation are detailed, and a trouble-shooting section is included on the causes of, and cures for, common industrial problems related to metalworking fluids.

This revised and expanded Third Edition contains 21 chapters summarizing the latest thinking on various technologies relating to metalworking fluid development, laboratory evaluation, metallurgy, industrial application, fluid maintenance, recycling, waste treatment, health, government regulations, and cost/benefit analysis. All chapters of this uniquely comprehensive reference have been thoroughly updated, and two new chapters on rolling of metal flat sheets and nanoparticle lubricants in metalworking have been added. This must-have book for anyone in the field of metalworking includes new information on chemistries of the most common types of metalworking fluids, advances in recycling of metalworking fluids, and the latest government regulations, including EPA standards, the Globally Harmonized System being implemented for safety data sheets, and REACH legislation in Europe.

DISCUSSION IN THIS CHAPTER PERTAINS TO fluids that facilitate metalworking and machining operations. The nature of the various working operations is examined, along with the properties of the lubricants needed for each. Discussion includes metalworking fluid classifications, composition, formulating, and testing. Representative examples of the various metalworking fluid formulations are also provided at the end of the chapter. Metalworking is the process of converting the bulk metal into a component, or a part, and primarily involves two types of operations: Those that produce metal debris and those that produce no debris. The former type is classified as the metal removal operations and the latter type is classified as the metal forming operations. Cutting and grinding are examples of the first type and drawing, stamping, and bending are examples of the second type. All metalworking operations involve bringing two solids, a tool and a work-piece, together to create a new part or a shape. The process involves high friction, high pressures, high temperatures, and tool wear, and it is the job of the lubricant, or the metalworking fluid, to control them. Metalworking fluids accomplish this by providing cooling, lubrication, and protection against corrosion. They, therefore, improve the efficiency of the operation, and hence increase productivity. Irrespective of the type of the metal cutting operation, whether it is turning, milling, drilling, planing, shaping, broaching, or sawing, the mechanism of action of all cutting tools is the same. That is, the cutting is performed by the tool either as it moves across the metal surface being machined, or the tool is stationary and the metal surface moves against it. In either case, the process is accompanied by plastic deformation of the metal surface at the front of the cutting edge of the tool and the rubbing of the formed chip with the tool surface, as shown in Fig. 11.1. The temperature estimates in the cutting zone are 900C on the tool's cutting edge, 500C on the chip, and 200C on the work-piece. As we move away from this zone, the temperature of the tool drops to 400C on the tool's outer edge and to 200C on the chip. About 75% of the heat generated is due to the deformation of the metal and the other 25% results from the friction due to sliding of the chip on the tool face. Metal deformation occurs due to shear or plastic flow along the shear plane that extends from the edge of the tool to the surface of the work-piece metal, see Fig. 11.1. Below the shear plane the metal is undisturbed; above it the metal is deformed and ultimately results in the formation of a chip. It is critical that the high temperatures in the cutting zone are decreased, otherwise extensive tool wear and rough finish of the work-piece will occur. In the case of the brittle materials, high temperatures in addition may cause the fracture of the metal along the shear plane, which will form a discontinuous or segmentai-type chip. This is undesired since it will interrupt the continuous cutting action. In the case of the ductile metals, high temperatures will also cause a built-up-edge on the nose of the tool, which will result in a severe plowing action and again poor finish of the work-piece surface will occur. The built-up edge is the stagnant mass of the metal that sheared away from the body of the chip by the high tool-face friction.

The application of metal cutting fluids is an integral part of industrial machining operations. Minimum quantity lubrication (MQL) is the latest form of cutting fluid application method currently used by several manufacturing organizations. This book consolidates all the available knowledge in terms of the application of different processes as well as materials in a concise fashion in one reference resource. Sustainable Machining Using MQL Application of Cutting Fluids offers a detailed discussion of the MQL mechanism in cutting fluid applications. It highlights the influence of MQL parameters on different workpiece materials and provides sound explanations along with photographs for all technical reasonings. The book presents the usage of both micro and nano cutting fluids in machining for sustainability while it also captures the knowledge in the field including the recent research outputs, as it illustrates a comprehensive coverage of MQL practical application. This book should be on the bookshelf of industrial engineers, those working in production and manufacturing, process designers, tool material designers, cutting tool designers, and quality specialists. Researchers, senior undergraduate students, and graduate students will also find this book full of very helpful reference information.