Skill Builders

Quaker's Skill Builders address a wide range of metalworking topics. They were created to help customers tackle their issues with greater expertise. We hope this documentation improves your knowledge and helps you better understand these issues. Check back frequently to see new Skill Builders as they are added to the site.

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GENERAL AREAS

Amines

Cutting and grinding fluids often contain chemical compounds called “amines.” This “Skill Builder” will give you a basic knowledge foundation about amines and metalworking fluids.

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Ammonia

Ammonia is a clear, colorless gas with a sharp, characteristic odor. It is lighter than air and very soluble in water. Ammonia release from metalworking fluids is an unfortunate consequence that leads to employee dissatisfaction, lost of work time, temporary plant closures and potentially poor worker health.

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Analytical

Many people are fascinated by the television show called CSI (Crime Scene Investigations). It does not matter if the CSI Laboratory is based in Las Vegas, Miami or New York City, the end result is that these crime fighters help turn the evidence into facts that convict the criminals.

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Concentration

The term “water-soluble metalworking fluid” means that the fluid is mixed with water prior to use in the machine tool. However, unlike straight oils, water-soluble products must be monitored for appropriate concentration. What exactly is being monitored or measured?

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Dermatitis

Dermatitis creates an unpleasant condition often accompanied by scratching or itching which then exacerbates the situation. It is reaction to and managing the situation that becomes important.

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Dust Suppression

Dust can create problems that impact operational efficiency, impair visibility, increase accident risk, and have detrimental effects on the health of workers and the environment. To address these issues, companies in different industries use dust suppression, which is a continuous and costly activity that requires a large amount of water on a regular basis.

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SDS

Read a Safety Data Sheet (SDS) and one will quickly understand that the regulatory world is full of jargon, acronyms and abbreviations. This “Skill Builder” will help with reading and understanding a Safety Data Sheet.

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Oils

Mention “lubrication” and the world thinks of oil. Yet, for something so important to the world’s economy, there are many misconceptions about oil. To be an effective seller of cutting and grinding fluids, one should know the basics of petroleum.

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QCMSSM Best Practices

Quaker Chemical Management Services (QCMSSM) utilizes the principal of sharing best practices among sites which saves time, and makes the work easier, and saves the customer money.

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Terminology

Most industries, groups and organizations have their own set of abbreviations, acronyms, phrases, and other terminology. The metalworking industry is no different.

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Test Methods

During product development of metalworking fluids, many tests are run to determine the physical, chemical and performance properties of the fluid which are often compared to a previous product or a competitive fluid.

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PROCESSES AND PERFORMANCE

Grinding

Metal removal fluids (MRF) are used for both machining and grinding applications. As was discussed in the basic training, both applications are similar in that there is an interface between the cutting tool, the metal being cut (i.e. the workpiece) and the chip that is created.

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Machinability Ratings

There are many different metals commercially available. Some are easier to machine than others. Many years ago, a system was developed to rate the relative ease or difficulty of machining various metals. These ratings are called “Machinability Ratings.”

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Machine Tools

Metal removal fluids (MRF) are used in machine tools to provide lubrication, cooling of the tooling and parts, and to provide chip removal to the filtration systems. What exactly is a machine tool? It is simply a powered device used to fabricate metal components.

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Metallurgy

Understanding the basics of metallurgy provides sufficient background to know how the various metals we encounter differ. These differences impact the types of fluids chosen for the individual operations.

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Surface Finish

In metalworking, some customers are very concerned about this texture in what they refer to as the “surface finish” of the part. Some metal components or parts must have extremely smooth surfaces to function properly.

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Feeds, Speeds & Depth of Cut

The choice of feed, speed and depth of cut must be based on the customer’s objectives. What is their goal in this application? Do they want to manufacture parts faster or maximize tool life? How important is the surface finish and dimensional accuracy of the part?

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SYSTEM MANAGEMENT

Bugs

Metalworking fluids are subject to attack by micro-organisms. Many people refer to these micro-organisms as “bugs.” Microbiology is a specialized field but understanding some basics about these organisms can help to avoid problems.

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Corrosion I

Metalworking processes employ oil-based, solvent-based and water-based fluids to interact with the various metals. At some point, the issue of protecting these metals from corrosion or staining is important to your customers.

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Corrosion II

A Proactive Approach to Preparing for Spring – the Rust Season. The warm temperatures of Spring are always a welcomed change; however, along with warmer weather comes higher temperatures, higher humidity and, unfortunately, rust.

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Corrosion III

In many coil or parts production processes, application of corrosion preventives is the final step. Protection of the coil or part from rust is critical to the transit or storage of the metal/part.

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Dump, Clean & Recharge (DCR)

While a DCR sounds simple and straightforward, there are things that have to be communicated to make sure that it is done properly and in a timely fashion.

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Filtration

Most, but not all, metalworking systems have some form of filtration. Whether it is a system for coolants, cleaners, stamping fluids or corrosion preventives, the intent is generally the same. The purpose of filtration is to remove contaminants. This “Skill Builder” will focus on positive filtration.

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Greases

A grease is a solid to semi-fluid product of dispersion of a thickening agent in a liquid lubricant. Other ingredients imparting special properties may be included as additives.

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Lubrication Tests

One of the challenges when investigating a lubricant application has to do with determining how much lubrication is needed. There are many different laboratory tests that can be run to evaluate the lubrication provided by a product.

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Monitoring Dilution Ratio

One of the most important process variables in die casting is the dilution ratio. The dilution ratio is the ratio at which a die lubricant is diluted in water prior to being sprayed onto the die. Unfortunately, there is no one optimal dilution ratio, as this is something that must be established based on each unique application and die cast machine.

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Recycling Fluids

The concept of recycling fluids has been around for a while. The focus of waste reduction is typically called “Reduce, Reuse & Recycle.”

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Samples

At some point in time it becomes necessary to take a sample of a fluid for some type of analysis. However, not all fluids should be sampled in the same manner.

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Tramp Oil

Tramp oil is probably one of the most common contaminants in metalworking fluids. Whatever the source, tramp oil is a foreign contaminant that can create the problems detailed in this “Skill Builder.”

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Quintolubric Q-Trak

Quaker manufactures and sells fire resistant hydraulic fluids (FRHFs) under the brand name QUINTOLUBRIC®. Routine analysis of these fluids is sent to
Quaker laboratories in Conshohocken, PA to the Q-TRAK lab. This lab assesses the FRHFs in a number of areas as detailed in this “Skill Builder.”

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Water Quality

Cutting and grinding coolants, diluted for use, are mostly water (95% water at a typical concentration). Water plays an important role in coolant performance. We need to understand how water affects metalworking coolants. This “Skill Builder” makes water crystal clear.

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