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Iodo propynyl butyl carbamate (IPBC) has been used as a fungicide in metal‐working fluid formulations for a number of years. While traditional laboratory evaluations show excellent performance, results in the field are often disappointing. An in‐depth review of the biocide’s physical and chemical characteristics has helped us predict these performance differences better.

This paper aims to formulate a new metal working fluid (MWF) composition including some eco-friendly emulsifiers, corrosion inhibitor, biocide, and non- edible vegetable oil (castor oil) as the base oil. To achieve this aim, five MWFs with different hydrophilic–lipophilic balance (HLB) value as 10, 9.5, 9, 8.5 and 8 were prepared to identify the optimum HLB value that gives a highly stable oil-in-water emulsion. The performance of castor oil based MWF was evaluated using tool chip tribometer and drill dynamometer. The surface morphology of steel disc and friction pin was performed using scanning electron microscope (SEM) and 3D profilometer. The results revealed that the use of the prepared cutting fluid (E1) caused the cutting force to decrease from 500 N for dry high-speed steel sample to 280N, while the same value for a commercial cutting fluid (COM) was recorded as 340 N at drilling speed and cutting feed force as 1120 rpm and 4 mm/min., respectively.

A castor oil-based metalworking fluid was prepared using nonionic surfactants. The composition of the metalworking fluid was further optimized by adding performance-enhancing additives. The performance of castor oil based MWF was analyzed using Tool chip tribometer and Drill dynamometer. The surface morphology of steel ball and a disc was done using 3D profilometer and SEM.

Studies revealed that castor oil-based MWF having Monoethanolamine (MEA) as corrosion inhibitor was found to be highly stable. The drilling dynamometer and tool chip tribometer studies showed that castor oil-based MWF performance was comparable to that of commercial MWF.

This study aims to explore the performance of the castor oil based metalworking fluid (MWF) using tool chip tribometer and drill dynamometer.

The conventional MWFs are petroleum derives and are unsustainable. Use of non-edible plant-based oils for preparing the MWF will not only be conserved environment but also add value addition to agricultural crops.

The social Implications is aiming to decrease the environmental impact that results from the using of mineral cutting fluids.

The originality of this work is to replace the mineral oil and synthetic oil based cutting fluids with more eco-friendly alternatives one. In addition, the investigation will focus on developing functional additives required for cutting fluids which are environmentally benign.

The purpose of this paper is to provide a practical review of metal working fluids and their implications to the machining practice. Despite their widespread use and applications, there are several scientific and economic factors that call for an investigation of current practices and development of new approaches.

There are numerous methods that diverge from traditional “wet” machining, which move towards an environmentally friendly and cost effective machining process. This includes looking at both minimum quantity lubrication and dry machining as methods to reduce recurring costs, lower health care premiums associated to metalworking fluid exposure, and to minimize the environmental footprint attributed to machining.

Traditional machine lubrication techniques are in use today despite a lack of scientific or economic evidence that they function efficiently. Depending on the machine type and material used, there are several possible methods that can minimize or eliminate metalworking fluids from the machining process.

This paper provides a practical assessment of current industrial practices and offers opportunities for improvement from both an economic and an environmental perspective.

This paper provides an overview of previously conducted research to suggest areas of improvement in manufacturing processes utilizing metalworking fluids.

In the late 19th century, work attributed to a Mr F. W. Taylor showed that water flooding a cutting area permitted a great increase in cutting speeds. Prior to this cutting was performed dry, at very slow speeds, but it was found that water gave an easier removal of swarf, enabling the cutting speed to be increased by some 40 to 50%. Water, obviously, gave rise to the problems of corrosion.

When replacing a complex component formulation of the company’s premium industrial EP gear oils, a suitable additive pack was selected based on extended EP and other tests, and critical applications were identified. To satisfy the most critical application, a number of laboratory tests were done, using various combinations of additives, followed by a field trial. This paper describes some of these laboratory tests, e.g. rust tests. The final product was tried and accepted by the customer replacing the old well‐proven formulation.

The metal working fluid industry accounts for approximately 5 per cent of the total world market for lubricant. Cutting fluids are formulated to fulfil one or more different functions. It is becoming increasingly apparent that to provide additions friendly for environment and low costs. This paper studies high performance mixture of anionic/nonionic polymeric surfactants as an additive for metal working fluid, thus the mixture has poly functions such as anticorrosion and emulsifier. The surface tensions of aqueous solutions of anionic/nonionic mixtures were measured as a function of nonionic concentration at 40°C with constant anionic concentration. The surface excesses concentrations, mole fractions, and interaction parameters of binary polymeric mixtures were calculated. Moreover, the critical micelle concentration and adsorption of ANO/ETH mixture on solutions and steel surface were determined. These parameters confirm the synergistic action of ANO/ETH polymeric surfactants for micellization and adsorption at different interfaces.

The purpose of this paper is to evaluate the cooling ability of minimum quantity lubrication (MQL) cutting fluid.

An experimental system is devised to find the heat transfer coefficient of MQL under simulated reaming conditions. Cooling rate of the specimen is measured with an infrared camera. The effect of air pressure and oil volume on cooling rate is tested. Metal cutting tests are performed to evaluate the effect of heat transfer coefficient on workpiece temperature.

Convective heat transfer coefficient for MQL increases with increasing air pressure. Oil volume has an indeterminate effect on the heat transfer coefficient; however, it is a dominant factor for controlling temperature during reaming.

The results of the study can provide guidance to optimize the temperature controlling ability of MQL for production.

There is limited information available in literature regarding the heat transfer coefficient of metal working fluids, particularly for MQL. In particular, experiments designed to investigate the effect of air pressure and oil volume on the heat transfer coefficient of the mist have not been previously documented. This information may be used to improve the overall cooling ability of MQL mist, thus increasing its effectiveness at controlling tool wear and maintaining part quality. The other major contribution of this work is to separate the role of the cooling and lubrication for controlling temperature while reaming aluminum. Prior to this study, there has been relatively little research performed for the reaming metal cutting operation, and still less for reaming with MQL. The nature of how metal working fluids control temperature is not fully understood, and this work provides insight as to whether cooling or lubrication plays the dominant role for reaming.

SYNOPSIS. A new type of cutting fluid is essential to achieving utilisation of the full potential of Automated Machining (AM). Coolant capabilities frequently determine the scope of multi‐tool machining applications. Identifying operational needs and overcoming AM system constraints has provided a unique opportunity to develop a new synthetic cutting fluid technology. A vision for the future is where the expansion of synthetic lubricant technology will continue to contribute significant benefits to an ever‐widening area of manufacturing industry's lubricant requirements.

No one particular fluid has cooling and lubrication properties suitable for every metalworking application. The purpose of this paper is first, to investigate the effect of anionic and nonionic mixed emulsifier system in stabilization of cutting fluid formulations and second, to study the interaction synergism of the fulfill additives of metalworking fluids to achieve low scar diameters, high stability, anti rusting and corrosion properties.

A lot of set mixtures in this work were formulated to get the demand needed for soluble oil metalworking fluids. It was based on a blend of emulsifier package (anionic‐non ionic), and in order to reach acceptable manufacturing conditions, coupling agent, stabilizer, biocide, base oil and anti‐rust additives were added to the formulation. Different percentages of these components were incorporated to optimize the stability of the emulsifier system. Standard tests were carried out to evaluate the performance of oil‐in‐water (O/W) emulsions as lubricating and cooling fluids in machining operations. The evaluation was drawn in five factors; oil stability, emulsion stability, pH, anti‐rust (corrosion inhibition), biological activity and extreme pressure performance tests.

All tests achieved excellent results according to the ASTM. From the obtained results, the formula (named EPRI 950) exhibited a good performance compared with the commercial cutting fluid.

This work investigates the effect of anionic and nonionic mixed emulsifier system in stabilization of cutting fluid formulations; and the interaction synergism of the fulfill additives of metalworking fluids to achieve low scar diameters, high stability, anti‐rusting and corrosion properties.