Formulating Synthetic Cutting Oil

What is synthetic cutting oil?

Synthetic cutting oil is a metalworking fluid that is made from synthetic chemical compounds, rather than mineral oil. It is a transparent, water-soluble fluid that is used to cool and lubricate cutting tools and workpieces during machining operations.

Difference between synthetic cutting oil & other mineral oil based cutting oil

  • The main difference between synthetic cutting oil and mineral oil based cutting oil is their composition. Synthetic cutting oil is made from synthetic chemical compounds & absolutely free from mineral oils .While mineral oil based cutting oil is made from petroleum distillates.
  • This difference in composition results in a number of different performance characteristics, including:
  • Synthetic Cutting Oil – Does not contain mineral oil & they form a clear transparent solutions when diluted with water
  • Semi Synthetic/ Soluble oil – Contains mineral oil & forms milky white solution when diluted with water

Difference with respect to the performance

  • Heat Transfer performance: Synthetic cutting oil typically offers higher heat transfer capacities than mineral oil based cutting oil. This is because synthetic cutting oil has a lower viscosity and a higher thermal conductivity.
  • Coefficient of Friction: Synthetic cutting oil typically has a higher lubricity than mineral oil based cutting oil so possess lower coefficient of friction . This is because synthetic cutting oil contains additives that reduce friction and wear.
  • Sump life: Synthetic cutting oil typically has a longer sump life than mineral oil based cutting oil. This is because synthetic cutting oil is less prone to oxidation and breakdown.
  • Environmental impact: Synthetic cutting oil is typically more environmentally friendly than mineral oil based cutting oil. This is because synthetic cutting oil is less toxic and biodegradable.

Formulating Synthetic Cutting Oil

The formulation of synthetic cutting oil is a complex process that involves the selection and blending of the appropriate base & mixing additive according to specific use & application. The specific synthetic cutting oil formulation will depend on the specific machining operation and the type of metals being machined.  Based on formulators & customers demand one can add synthetic esters or olefins to increase oil phase in the formulation.

Components of Synthetic Cutting oil formulation

Synthetic ester base
Amine free rust & corrosion inhibitors
Chlorine free EP additives
Biocides

Formula of Synthetic Cutting Oil

Synthetic BLB – 40 to 50 %
DM Water – 15 to 25 %
Rust Inhibitors/ Corrosion Inhibitors – 5 to 10 %
Anti-Wear Additives – 5 to 10 %
Biocides – 0.5 to 1 %

Appearance – Clear oil
PH of concentrate: 9 to 10
Odour - Chemical

Compatibility:  Synthetic BLB are compatible with most additives so forms stable thermally stable solutions

Water Dilution

DM- 100 Kg
Product- 5 Kg  
Appearance of Dilution: Clear & Transparent

Benefits of Synthetic Cutting Oil

  • Forms a cleaner transparent water white solution
  • No Oil layer formation
  • No bad odour from the sump
  • Does not form mist
  • Improve the surface finish

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