Metalworking fluids (MWFs) are used in a variety of machining and forming operations to lubricate, cool, and clean the workpiece and tool. They also play an important role in preventing rust and corrosion..

Types of Metal Working Fluids

• Straight oils/ Neat Oils- Composed of mineral or synthetic oils. Straight oils are not diluted with water.
• Soluble oils- Containing anywhere from 70 to 80 percent mineral oils and additives, surfactants to dissolve the oil in water.
• Semisynthetic fluids- Containing 20 to 40 % mineral oils & the remainder additives.
• Synthetic fluids.  No mineral oil in the formulation . These fluids offer excellent performance over all types of fluids & very difficult to design as required many other additives to replace role of mineral oils. Components of synthetic fluids are not easily compatible with most metal working additives which are used for semi synthetic water based cutting oils or soluble oils

MWF additives are essential for improving the performance of MWFs and meeting the specific requirements of different machining operations and metals. Some of the most important functions of MWF additives include:

• Lubrication: MWF additives reduce friction and wear between the workpiece and tool, which can prolong tool life and improve the surface finish of the workpiece.
• Cooling: MWF additives help to remove heat from the cutting zone, which can prevent thermal damage to the workpiece and tool.
• Cleaning: MWF additives help to remove chips and other debris from the cutting zone, which can improve the quality of the machined surface and reduce tool wear.
• Rust and corrosion prevention: MWF additives form a protective layer on the workpiece and tool to prevent rust and corrosion.

Types of MWF Additives

There are a variety of different types of MWF additives, each with its own unique properties and functions. Some of the most common types of MWF additives include:

• Lubricity Additives:  Improves surface finish & dimensional accuracy
• Extreme Pressure (EP) Additives: EP additives form a protective layer on the workpiece and tool under high pressure and temperature conditions, which reduces friction and wear.
• Rust Inhibitors: Highly useful where water soluble fluids to avoid  flash rusting of work piece  
• Anti-wear Additives: Anti-wear additives form a thin film on the workpiece and tool to reduce friction and wear.
• Biocides: Biocides prevent the growth of bacteria in MWFs, which can extend the life of the MWF and improve its performance.
• Corrosion inhibitors: Corrosion inhibitors form a protective layer on the workpiece and tool to prevent rust and corrosion.
• Anti-foaming agents: Anti-foaming agents reduce foam formation in MWFs, which can improve the performance of MWFs and prevent machine tool problems.
• Stabilisers : Maintain the formulation in single phase , increases the stability
• Chip Removal Agents : Promote carry over of the chips  & particles
• Wetting Agents : Forms a layer on the cutting  tool & work piece to avoid direct contact

Importance of metal working additives

Metalworking fluid additives are essential for improving the performance of MWFs and meeting the specific requirements of different machining operations and metals. By carefully selecting and formulating MWF additives, manufacturers can produce MWFs that provide optimal performance and protection.

Selection of MWF Additives

Uses of additive make your final product unique which offer excellent performance even for most critical applications. The selection of MWF additives depends on a number of factors, including the type of fluid you are proposing to the operation, machining operation, the metal being machined, and the desired performance characteristics of the MWF. It is important to consult with a MWF specialist to select the right additives for your specific application.

• Chemical compatibility: All these are called as metal working additives but they are speciality chemicals & possess unique physical & chemical properties. Hence it is also important to consider the compatibility of different MWF additives. Some additives can react with each other and form undesirable compounds.
• Percentage of use : Every additive based on its concentration vary with use percentage
• Incorporating of the additive : Every additive is unique so as its SOP of mixing
• Stability :  Additives must increase the stability of   original product &   stability in the machines when used with  dilutions
• Cost of the Additive: The cost of MWF additives can vary significantly. Formulators should balance the cost of additives with the desired performance of the MWF.
• Environmental Impact:  it is important to consider the environmental impact of the additives. Some MWF additives can be toxic to aquatic life or may not be biodegradable. Formulators should choose additives that have a minimal environmental impact.
• Worker Health: MWF additives can also be hazardous to workers' health. Formulators should choose additives that are safe to handle and use.
• Operational Safety : Definitely metal working additives help to improve performance but at the same time , formulator has to consider operation safety  

By considering all of these factors, formulators and manufacturers can produce MWFs that meet the needs of their customers and comply with environmental and safety regulations