Safe way to work with metalworking fluids

The use of metalworking fluids (MWFs) in machining is widely recognised. In 2015, Asia is predicted to reach 5% growth says Research firm Kline & Company Inc. Growth will be driven not only by an increase in the domestic demand, but also as a result of continuing relocation of manufacturing facilities from high cost economies to low cost economies.

In many cases, exposure to metalworking fluids causes: irritation of the skin/dermatitis, occupational asthma, bronchitis, irritation of the upper respiratory tract, breathing difficulties or, rarely, a more serious lung disease called extrinsic allergic alveolitis (EAA), which can cause increasingly severe breathing difficulties in recurrent episodes, following repeated exposure. 

Recent developments are being undertaken by The Health and Safety Executive (HSE), a national independent watchdog for work-related health, safety and illness, concerning the safe use of water-based metalworking fluids.

Water-based metalworking fluids
Water-based Metalworking Fluids (MWFs) are used during the machining of metals to provide lubrication and cooling. Sometimes they are referred to as cutting fluids, suds, coolants, slurry or soap. They are generally used within the concentration range 2-10% depending on the application. The supplier's literature should be consulted for specific information. They can be:

? Soluble oil (emulsifiable oil) – These emulsifiable oils are combinations of highly refined petroleum oils, emulsifiers and other additives. They are used where cooling is important and are relatively cheap.

? Semi-synthetics – These are a hybrid of water soluble and synthetic, containing lower levels of highly refined petroleum oils with emulsifiers and other additives. They often appear translucent as the oil is a microemulsion. These fluids are versatile and especially useful in metal removal applications.

? Synthetics – These contain no petroleum oil, but are made from a range of chemicals. They tend to be used where cooling is important.

During use they can produce mists, the extent to which this occurs will depend on the nature of the fluid and the machining operation.

Neat oils are not specifically included in this SIM although the principals of effective fluid management still apply to these oils. Neat oils contain about 95% highly refined mineral oils, with some additives to improve performance. They are used neat without mixing with water where lubrication is more important than cooling (e.g. in very arduous operations). Low viscosity oils have an increased tendency to form mists in contact with rapidly rotating machinery. As they do not contain water, they have high resistance to bio-fouling. They should not be used if they contain mineral oils that are not highly refined;
As water contains microorganisms, diluted MWFs have a propensity for bio-growth, and thus traditionally contain a biocide. However, some MWFs have been formulated to be less susceptible to degradation by bacteria and to provide a long service life, but these fluids may also contain biocides.

Bioconcept & Biostable
Demand for MWF in Asia continues to grow at a healthy rate, sustaining an average 3.3% annual growth rate over the last three years. The continued vitality of the Chinese and other regional manufacturing industries has spurred consumption of metalworking and other industrial fluids across all categories. It is important to be aware of the differences between "bioconcept" and "biostable" MWF, and between them and other fluids. There are implications for the way in which HSE's guidance on the management of MWFs is interpreted, although the need for good management of the fluid is unchanged.

A characteristic of bioconcept fluids is that MWF systems will not have to be monitored for bacterial contamination by users nor will biocides need to be added. However, tMens Running Shoes