What are the common problems encountered during the use of cutting fluid products from manufacturers?

Products from cutting fluid manufacturers play a crucial role in metalworking processes. However, in actual application, a series of problems are often encountered, which can affect machining results, equipment lifespan, and operators' health. The following will elaborate on the common issues during the use of cutting fluids, covering aspects such as spoilage and foul odors, corrosion, excessive foaming, skin allergies, and abnormal concentration and pH levels.

1. Spoilage and Foul Odors
The spoilage and foul odor of cutting fluids are among the most common issues during use, primarily caused by bacterial growth. Both aerobic and anaerobic bacteria exist in cutting fluids. Aerobic bacteria divide every 20–30 minutes under aerobic conditions, while anaerobic bacteria divide once an hour in anaerobic environments, releasing SO₂ with a rotten egg smell through metabolism, which causes the cutting fluid to turn black and stink. There are various ways bacteria can enter the cutting fluid, such as bacteria in the water during preparation, airborne bacteria, cross-contamination during workpiece transfer between processes, poor personal habits of operators, and poor cleanliness of machine tools and workshops. Furthermore, if the cutting fluid is not cleaned for a long time, impurities deposited in the tank and mixed-in tramp oil will become a breeding ground for bacteria, accelerating the spoilage and foul odor of the fluid.
 

2. Corrosion Issues
Cutting fluids may cause corrosion to metal materials and machine tool paints. Factors that can lead to corrosion include a low proportion of concentrate in the cutting fluid, excessively high or low pH values, high environmental humidity, using paper or wood to support workpieces, stacking of components, and excessive bacterial counts in the cutting fluid.
3. Excessive Foaming
Excessive foaming during the use of cutting fluids can negatively impact machining results and the normal operation of equipment. Causes of foaming include a low cutting fluid level, excessively high flow rate, too many right angles in the tank design, a nozzle angle that is too direct, and a high content of surfactants in the cutting fluid. Excessive foam reduces the cooling and lubricating performance of the cutting fluid, affecting machining precision and surface quality. It also pollutes the machining environment and brings inconvenience to production personnel.
4. Skin Allergies
Some operators may experience skin allergy symptoms after using cutting fluids. This is mainly caused by an excessively high pH value, poor quality of raw materials, an unstable formulation system, and excessively high levels of biocides and antibacterial agents. Additionally, operators with damaged or injured skin, or prolonged exposure to cutting fluids, face an increased risk of allergies.
 

5. Abnormal Concentration and pH Levels
Insufficient cutting fluid concentration impairs its cooling, lubricating, and rust-preventing properties, leading to reduced machining quality and accelerated tool wear. Conversely, excessive concentration can cause waste, increase costs, and potentially have adverse effects on machining equipment and workpieces. Abnormal pH levels are equally critical. A low pH value increases bacterial growth, leading to spoilage and foul odors, while reducing rust-prevention performance. A high pH value can cause corrosion to certain metal materials.
6. Other Issues
Cutting fluids may also experience problems such as phase separation and precipitation. These are usually caused by an unreasonable formulation, improper storage conditions, or contamination. Phase separation and precipitation affect the uniformity and stability of the cutting fluid, reducing its effectiveness.
Conclusion
In summary, cutting fluid products face numerous issues during use, including spoilage and foul odors, corrosion, excessive foaming, skin allergies, abnormal concentration and pH levels, as well as phase separation and precipitation. These problems not only affect machining quality and reduce production efficiency but may also harm operators' health and damage equipment. Therefore, when using cutting fluids, it is necessary to strictly follow standard operating procedures, strengthen daily management, and conduct regular testing and maintenance to ensure stable performance. Meanwhile, cutting fluid manufacturers should continuously optimize product formulations and improve product quality to provide users with superior and more reliable cutting fluid products, meeting the demands of the metalworking industry.