In modern industrial manufacturing, grinding fluids are an essential material. They not only improve processing efficiency and quality but also extend the lifespan of cutting tools. Grinding fluids have a wide range of applications, from mechanical processing to automotive manufacturing, to high-precision fields such as aerospace.
This article aims to introduce the characteristics, types, usage methods, precautions, and subsequent treatment of grinding fluids, hoping to provide some reference and assistance for the application and management of grinding fluids.
What is a Grinding Fluid?
Grinding fluid is a liquid widely used in metalworking for grinding and cutting metal surfaces. It can be water-based or oil-based, with oil-based fluids typically used for high-speed and heavy cutting applications, while water-based fluids are used for low-speed and light cutting applications. Grinding fluid can improve cutting efficiency and surface quality, while reducing tool wear and workpiece heat deformation.
Typically consists of several main components:
Base liquid:
Water or oil is the base liquid in grinding fluid. Water-based grinding fluid can effectively cool and lubricate metal surfaces, while oil-based grinding fluid can provide better lubrication.
Additives:
Additives are another important component of grinding fluid. They can improve the performance of the fluid, such as antimicrobial agents to prevent microbial growth in the fluid, rust inhibitors to protect metal surfaces from corrosion, and antioxidants to maintain the stability of the fluid.
Grinding particles:
Grinding particles in the fluid are the main component for achieving grinding and cutting. The particles can be ceramic, glass, or metal, and their size and shape can be adjusted for different applications.
Type of Grinding Fluids:
The performance of grinding fluid depends on its composition and formulation. Below are some common types of grinding fluids:
Water-based Grinding Fluid:
Water-based grinding fluid is composed of water and additives. It is commonly used in low-speed and light cutting applications, such as grinding and polishing.
Oil-based Grinding Fluid:
Oil-based grinding fluid is composed of oil and additives. It is commonly used in high-speed and heavy cutting applications, such as drilling and milling.
Synthetic Grinding Fluid:
Synthetic grinding fluid is a mixture of various chemical components such as water, oil, and additives. Its type and performance vary accordingly. Grinding fluid can provide different effects such as lubrication, cooling, cleaning, and anti-corrosion to meet different cutting processing needs. Compared to traditional manual grinding methods, using grinding fluid can greatly improve production efficiency and product quality, reduce labor costs, and tool wear, thus playing an important role in industrial production.
Synthetic grinding fluid is a new type of grinding fluid developed in recent decades. Compared to traditional water-based and oil-based grinding fluids, synthetic grinding fluid has superior performance. It can not only provide good lubrication and cooling effects but also has multiple properties such as antibacterial, anti-rust, and anti-oxidation. Due to its excellent performance, synthetic grinding fluid has been widely used in high-speed and heavy cutting applications.
How to Use Grinding Fluids:
Grinding fluids need to be prepared and diluted according to the requirements before use, and appropriate methods should be chosen to achieve the best grinding results. Here are some methods for using grinding fluids:
Grinding fluids are essential additives in metal processing. They have functions such as lubrication, cooling, and cleaning, which can improve processing efficiency and quality. The following are the basic steps and methods for using grinding fluids:
Preparation:
Before using grinding fluids, it is necessary to prepare the work area and necessary materials. Clean the processing area and tools, keep the environment dry and free of impurities. Prepare grinding fluids, containers, shakers, permeation test paper, etc.
Adjusting the concentration of grinding fluids:
Pour the grinding fluids into the container and add an appropriate amount of water according to the recipe to adjust the concentration of the grinding fluids. The choice of concentration should be based on specific processing conditions and requirements. Generally, low concentration will reduce processing quality, and high concentration will affect processing effects.
Constantly replenishing grinding fluids during processing:
During the processing, continuously replenish the grinding fluids to maintain the stability of the concentration and cooling effect of the grinding fluids. Generally, the grinding fluids should fill the processing area, and a shaker can be used to evenly disperse the grinding fluids.
Testing the performance of grinding fluids:
Regularly use permeation test paper to test the performance of the grinding fluids to ensure its normal operation. Through permeation tests, you can understand parameters such as the concentration, pH value, and impurity content of the grinding fluids, and whether it needs to be replaced or the concentration needs to be adjusted.
Regularly replacing grinding fluids:
After using grinding fluids for a period of time, its effectiveness will decrease due to the decomposition and dissolution of additives. Therefore, it is necessary to replace the grinding fluids regularly to ensure processing quality and efficiency.
When using grinding fluid, the following precautions should be taken into consideration:
Preventing contamination: Grinding fluid is prone to contamination, so attention should be paid to the cleanliness of the processing environment. Before using the grinding fluid, the processing area should be cleaned to prevent dust and impurities from entering the fluid. At the same time, tools and instruments should be kept clean to avoid cross-contamination.
Regular replacement:
After a period of use, the effectiveness of the grinding fluid may decrease due to the breakdown and dissolution of additives. Therefore, the fluid should be replaced regularly to avoid expiration or overuse affecting the quality of the processing.
Avoid over-concentration:
Over-concentrated grinding fluid will reduce its lubrication and cooling effects, leading to increased surface roughness, accelerated tool wear, and increased processing temperature. Therefore, the concentration of the grinding fluid should be noted to avoid over-concentration.
Proper concentration adjustment:
Low concentration of the grinding fluid will reduce its lubrication and cooling effects, making the tool easy to wear and causing thermal cracking on the processed surface. Therefore, the concentration of the fluid should be properly adjusted during use to achieve the best processing effect.
Proper adjustment of usage:
Grinding fluid has various usage methods, and the usage method of the fluid should be adjusted according to the shape, size, and material of the processing area to achieve the best cooling, lubrication, and cleaning effects.
Safety protection:
When using grinding fluid, protective clothing, gloves, masks, and other protective equipment should be worn to avoid contact with the skin, mouth, and eyes.
Air circulation:
When using grinding fluid, attention should be paid to ventilation and maintaining indoor air circulation to avoid the impact of oil fumes and gases generated by the fluid on the work environment and health.Storage method:
Grinding fluid needs to be stored in a dry and ventilated place, avoiding direct sunlight and high-temperature environments. The storage time of different types of grinding fluid also varies, so attention should be paid to the shelf life and storage method.
Cleaning and recycling: After using the grinding fluid, cutting tools and the working area should be cleaned promptly to avoid environmental pollution. Grinding fluid can also be recycled and reused to reduce waste and its impact on the environment.
Post-treatment of grinding fluid
After using grinding fluid, appropriate treatment is necessary to ensure environmental hygiene and safety. The following are common methods for post-treatment of grinding fluid:
Separation of liquid and solid:
Firstly, the solid and liquid components in the grinding fluid need to be separated. Separation can be achieved by using filters, centrifuges and other tools. The collected solids can be treated and stored appropriately, while the liquid can be further treated or recycled.
Neutralization or adjustment of pH value:
If the pH value of the grinding fluid is too high or too low, it may cause pollution and harm to the environment. Therefore, neutralization or adjustment of pH value is necessary. Neutralizing agents, alkaline substances, etc. can be added to neutralize acidic liquids, or acidic substances can be added to adjust alkaline liquids.
Recycling and reusing treated grinding fluid:
Grinding fluid can be recycled and reused to reduce resource waste and environmental pollution. Recycling methods include filtering, evaporation, precipitation, centrifugation, etc., while reuse methods include adding new additives and adjusting the concentration. It should be noted that the concentration, pH value, impurity content and other parameters should be carefully monitored during the recycling and reusing process to ensure effectiveness and environmental safety.
Disposal of waste grinding fluid:
If the grinding fluid cannot be reused, safe and environmentally friendly waste disposal is necessary. Generally, local environmental regulations and waste disposal standards should be followed, such as neutralization treatment, high-temperature incineration, landfilling, etc.
In summary, appropriate treatment of grinding fluid is necessary after use to ensure environmental hygiene and safety, and to achieve resource recycling and reuse, fulfilling corporate social responsibility.
Conclusion
The application of grinding fluid is not limited to metal processing, but can also be applied to other industries.
For example, in glass processing, grinding fluid can be used for surface polishing and glass cutting. In stone processing, grinding fluid can be used for surface finishing and stone cutting.
In semiconductor processing, grinding fluid can be used for the processing and polishing of semiconductor chips.
Therefore, grinding fluid plays an indispensable role in various industries.
In conclusion, as an important industrial liquid, grinding fluid has been widely used in industries such as metal, glass, stone, and semiconductor. Different types of grinding fluids have their unique properties and application ranges. With the continuous advancement and development of science and technology, it is believed that the performance and application of grinding fluids will be further improved and expanded.
