Lubricant and Coolant – Types, Necessity, Distribution System, Selection, Handling and Care
In the ITI Turner trade, machining operations generate heat and friction between the cutting tool and workpiece. To reduce this heat and improve machining efficiency, lubricants and coolants are used. These fluids play a vital role in increasing tool life, improving surface finish, and ensuring smooth operation. This chapter explains their types, necessity, distribution systems, selection for different materials, and proper handling.
Introduction to Lubricants and Coolants
Lubricants reduce friction between moving surfaces, while coolants remove heat generated during machining. In many cases, a single fluid performs both functions and is called a cutting fluid.
Necessity of Lubricants and Coolants
- Reduce friction between tool and workpiece
- Remove heat generated during cutting
- Improve surface finish
- Increase tool life
- Prevent rust and corrosion
- Flush away chips from cutting zone
Types of Lubricants and Coolants
1. Straight Oils
These are mineral oils used without mixing water.
- Good lubrication
- Used for low-speed operations
2. Soluble Oils
These are mixed with water to form an emulsion.
- Good cooling and lubrication
- Widely used in machining
3. Synthetic Fluids
Made from chemical compounds without oil content.
- Excellent cooling
- Long service life
4. Semi-Synthetic Fluids
Combination of synthetic and soluble oils.
- Balanced properties
- Good performance
System of Distribution of Coolant
1. Flood System
A large amount of coolant is directed continuously onto the cutting area.
2. Drip System
Coolant is supplied drop by drop.
3. Spray System
Coolant is sprayed onto the cutting zone.
4. Manual Application
Coolant is applied manually using a brush or can.
Selection of Coolant for Different Materials
| Material | Recommended Coolant |
|---|---|
| Mild Steel | Soluble oil |
| Cast Iron | Dry or air cooling |
| Aluminum | Kerosene or soluble oil |
| Brass | Dry or light oil |
| Stainless Steel | Synthetic coolant |
Factors Affecting Selection of Coolant
- Type of material
- Type of machining operation
- Cutting speed and feed
- Tool material
Handling of Lubricants and Coolants
- Store in clean containers
- Avoid contamination
- Use proper mixing ratio
- Follow safety guidelines
Care and Maintenance
- Regularly check coolant level
- Replace contaminated coolant
- Clean tanks and filters
- Maintain proper concentration
Advantages of Using Coolants
- Improves machining efficiency
- Reduces tool wear
- Enhances surface finish
- Prevents overheating
Limitations
- Requires maintenance
- May cause environmental issues if not handled properly
Safety Precautions
- Avoid skin contact
- Use protective equipment
- Ensure proper ventilation
- Dispose waste properly
Application in Turner Workshop
In the Turner trade, lubricants and coolants are used during turning, drilling, and threading operations. They help in achieving better machining results and prolong tool life.
Proper selection and use of coolants improve productivity and quality.
Conclusion
Lubricants and coolants are essential in machining operations. They reduce friction, remove heat, and improve surface finish.
Understanding their types, selection, and proper handling is important for efficient and safe operation.
In conclusion, correct use of lubricants and coolants ensures high-quality machining and longer tool life in the ITI Turner trade.