Managing the Turnover of Metalworking Fluids

Managing the Turnover of
Metalworking Fluids

In any metalworking facility, the proper selection and care of coolants is critical to the quality of your output and the overall efficiency of your operation.

It took time to identify the right fluids for your application and for your operation. Having found them, it is wise to start and maintain a program that manages them to your advantage. Such a program would come into play in the purchase of fluids, their receipt and storage, and the monitoring of their use. The information generated through formal fluid management and consumption tracking will yield benefits to your plant through the efficient and safe manufacture of products.

Coolant storage, for example, may be treated too casually, with fluids stored outside or in conditions which permit the ingress of moisture or other contaminants that can shorten the service life of the fluids. Similarly, many fluids have a limited shelf life, so fluid storage should be organized in a first-in first-out (FIFO) configuration, ensuring that the oldest fluids are used first. Finally, tracking fluid usage is important to defining a baseline pattern for your operation. Any significant deviations from this baseline could be symptomatic of a serious problem.

This is where we introduce the concept of fluid turnover rate.

Turnover Rate as a Diagnostic Tool
Let's assume we're looking at a machine tool operation. When that machine tool was newly installed, it took a certain amount of coolant concentrate to charge the system. Most coolant manufacturers recommend regular (or daily) additions to the fluid reservoir to replenish the additives consumed. These additions, of course, should be done in accordance with accepted mixing procedures.

Turnover rate is the time it takes for the system to use the amount of concentrate initially required to fill the sump. Rates vary by the type of fluid in use. For water soluble cutting fluids, 4-6 weeks might be an acceptable range; for semi-synthetic oils 6-8 weeks; and for synthetic oils 8-10 weeks.

Additionally, a number of other factors that vary from plant to plant affect turnover rate. These include spillage, leaks and evaporation; water hardness; biological contamination; number of machines running on the system; number of shifts per day, etc.

Many variables affect turnover rate, which is why a formal coolant management system can help establish an acceptable baseline for your operation. Any significant deviation from your baseline turnover rate should be a warning to managers to do an audit of the operation to correct any persistent problems.

High Turnover Rates Mean Short Turnover Times
A high turnover rate (again, relative to your baseline rate and consistent with manufacturer guidelines) means too much fluid concentrate is being used. This can be symptomatic of something as simple as a system leak, high levels of fluid carry-out on the product, or overspray and splash during operation. Other possible problems include high water hardness, bacterial consumption of concentrate, excess foaming, incorrect temperature of make-up water, etc.

Low Turnover Rate Means Long Turnover Times
A low turnover rate may save you money in fluid in the short run, but end up costing you more over the longer term. Your nose may be the first to tell you your turnover rate is too low. As the biocide in your coolant depletes, tell-tale odors may be symptomatic of a problem. Also, rust preventative additives will be depleted, so you will see more corrosion.

Acculube Wants to Help You Get it Right
If you suspect a fluids problem in your operation, call Acculube. Our fluid specialists are ready to help you diagnose and correct these problems and assist in setting up a fluid management program to keep turnover rates within acceptable limits.

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