Grinding Fluids
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Grinding Fluids Ekkard Brinksmeier University of Bremen and IWT Bremen, Bremen, Germany
Synonyms Cooling lubricants; Metalworking fluids
Definition Grinding fluids belong to metalworking fluids. These are engineering media which are used to allow for higher productivity in material removal processes, i.e., cutting and abrasive processes.
functions of coolants is to lubricate. This is achieved by reduction of the friction which results from energy conversion in the contact zones between tool and workpiece as well as between tool and chip. Heat dissipation, i.e., cooling of the workpiece and washing chips away from the contact zone, is a further important function of the coolant (Brinksmeier et al. 1999, 2004; Inasaki et al. 1993; Howes 1990). The combined lubrication and cooling effect reduces tool wear, enhances surface quality and dimensional accuracy of the workpiece, and allows for higher material removal rates. Cooling and lubrication requirements differ in every application and mainly depend on process conditions. Coolants should, ideally, be composed to suit each specific case. Every coolant consists of a base fluid, to which other products such as anti-wear, anticorrosion, or emulsifying agents (additives) are added. According to DIN 51385, coolants are divided into oil-based and water-based types (Brinksmeier et al. 1999).
Theory and Application Introduction Metalworking fluids (Brinksmeier et al. 2015) play a significant role in machining operations (in particular grinding) and have a substantial impact on tool life, shop productivity, and workpiece quality. In machining processes such as turning, milling, grinding, and many other material removal processes, metalworking fluids perform several essential functions. One of the main
Oil-Based Coolants
In order to decrease friction, at high pressures and temperatures during machining processes, it is necessary to create separation films (consisting of coolant and specific additives) between the solid surfaces of the tool and workpiece. Oil-based coolants normally consist of 80–95 % base oil and can be divided into four groups:
# CIRP 2016 The International Academy for Production Engineering et al. (eds.), CIRP Encyclopedia of Production Engineering, DOI 10.1007/978-3-642-35950-7_6428-3
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Grinding Fluids
Straight oils without additives Straight oils with chemically active additives Straight oils with surface-active additives Straight oils with chemically active additives and extreme pressure additives (additives that form stable adsorption layers)
Water-Based Coolants
For high cooling efficiency and washing-away capabilities, water-based emulsions or solutions are employed. Their main disadvantage is susceptibility to leakage oils and microbial effects making high-maintenance costs unavoidable. Furthermore, the water and oil phases must be separated before disposal. Water-based solutions consist of inorganic and/or organic substances and water and very seldom contain mineral oils. Water-based emulsion concentrates contain 20–70 % base oil (mostly min
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