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Slide 1. Welcome to the metalworking fluid control, and maintenance module. In this module you will get an insight on how to keep your metalworking fluid in good working order, and guidance, on how to clean out metalworking fluid systems. Slide 2. We will firstly cover the basics of metalworking fluid control. What contamination could potentially reduce the metalworking fluids performance, and finally, metalworking fluid maintenance, cleaning and mixing. Slide 3. To keep the metalworking fluid performing at it’s best, along with a healthy system tank, it is important to carry out the checks covered in the previous modules. We then need to action anything from the checks that are carried out. So, for instance, if the concentration check from your refractometer is showing a low or high concentration, then action will be required accordingly, to get the metalworking fluid back to it’s correct specification. So, either adding a strong or weak metalworking fluid mix in this case. It is always best practice to re-check the metalworking fluid after any addition, to make sure it is at the correct concentration. A low pH could be flagged up for a couple of concerns. Either the system has bacteria, or the concentration is running low. It is best to check the system for bacteria using the dipslide method, before adding any necessary biocide. Slide 4. If the dipslide reading is over 10^4, then an addition of Acticide 14 is required. It may also be the case, that the system has had a consistent problem with high bacteria levels. It will then benefit from a total drain and clean out. Please note!, Acticide 14 additions, are only permitted by trained personnel. Foaming can be caused by several things: it could be high concentration, soft diluent water used for mixing, or the metalworking fluid has become dirty, with tramp oil and swarf contamination. Fuchs provide a range of de-foaming agents, and water hardener. Please ask a member of the Technical Department for information to determine which product is suitable for your metalworking fluid system. Slide 5. Contamination within metalworking fluids can not only reduce it’s performance, but also increase possible health risks. Tramp oil being one of them, which may come from internal leaks within the machine, such as a hydraulic system, or from the slideway lubrication system. It is important to remove as much oil contamination as possible, this can be done by using oil skimmers, or a vacuum cleaning system, such as a Freddy. Slide 6. Contamination can also come from a build-up of metal and swarf. This can be caused by inadequate filtration systems in the machines. If allowed to build-up, it can cause the following 3 issues: Poor cutting performance. Reduced sump life. Skin abrasion, and risk of dermatitis. Slide 7. Metalworking fluid results and observations are best to be viewed on a record chart, so that trends can be observed. It is always best to record any tramp oil leaks on the chart, as this will identify the frequency of leaks, and will prompt the maintenance departments to fix any leaks. All results from the record chart usually get transferred on to our online database, Fluids Connect. Though the checks are important to keep the metalworking fluid within specification, it is also advised that metalworking fluid tanks should be cleaned out regularly, and a cleaning schedule can be created by using Fluids Connect. Slide 8. The following simple step by step guide to cleaning out a water soluble Metalworking fluid system has been provided by the HSE. This can be adjusted accordingly, for instance, if the machine is particularly dirty, then a flush and drain process, with a weak metalworking fluid mix can be introduced before going onto step 4. Slide 9. Mixing Guidelines. Soluble metalworking fluid concentrates are normally diluted at 3 – 20% with water. It is important that good water quality is used when mixing metalworking fluids. If soluble metalworking fluids are mixed by hand, care should be taken that the metalworking fluid concentrate is well mixed into water, until the desired concentration is achieved. The final concentration should be checked with a refractometer. Larger quantities of metalworking fluid emulsions are best prepared with mechanised mixing system, such as a Dosa tron mixer. Smaller quantities can be mixed by hand, in a separate, clean container. Even if the final concentration can be pre-set on automatic mixing apparatus, a refractometer should still be used for a final check, and the emulsion adjusted as necessary. Slide 10. Fluid mixing with a dosa tron pump is more accurate, and easier than mixing by hand. You will usually find them connected to oil barrels or IBC containers. The concentrate inlet, takes the neat oil from the barrel, or IBC. The water connector supplies the water, and the proportional mixer part will mix to the desired strength, strength. The metering adjustment dial allows you to adjust the concentration feed to your metalworking fluid tank. Slide 11. When handling any type of metalworking fluid, please take care and use the correct PPE. As a minimum, Nitrile gloves with additional safety gloves and safety glasses are required. Other control measures may also be necessary if you are working with metalworking fluids in confined spaces, or procedures that are prone to splashing, or mist generation. These will be covered in the Health & Safety modules. Congratulations, you have completed this module