BARCELONA, Spain – The 4th Symposium on Metal Removal Fluids demonstrated, in John Burkes words, that the factories of the future will be different, and so will the chemicals inside them.
The mid-September conference, organized by UEIL in partnership with ILMA and STLE, offered nearly 40 presentations by industry, academic and government experts on the global challenges that metalworking fluids pose, and possible solutions to them.
Major factors influencing the future of metalworking fluids include demands by organized labor, public pressures, and the resulting targeted chemicals, government regulations, and end user and formulator restrictions, said Houghton Internationals John Burke in his opening comments on the fluids and the factories of the future.
Targeted chemicals include borates, formaldehyde, chlorinated paraffins and alkenes, tungsten cobalt carbide, siloxanes, castor oils and many more, Burke said. People will stop using them, even when the science isnt clear.
Because there is an infrastructure to recycle used mineral oil, it will remain king because it can be reused over and over, he continued. Substitute chemistries, including many esters, will face disposal challenges.
Congruent chemistry is the vision to the future, Burke contended, explaining that the chemistries of machine oils (hydraulic fluids, way oils, spindle oils, gear oils, greases, etc.) must become not just compatible with the metalworking fluids with which they inevitably mix. They need to enhance the coolant performance, Burke said. Likewise, the chemistry for cleaners must also be based on the same platform so the chemistries work together. It can be done.
In 10 years, minimum quantity lubrication will gain but not be dominant; many chemistries will disappear; less metalworking fluid will be consumed per chip produced; and more water will be reused after treatment, Burke said. And the factory of the future will be managed by outside services more and more.
Innovations
Burke chaired the innovations track of presentations at the conference, and singled out three presentations as particularly valuable:
1. Frank Kroto of Lubrizol presented solid data on new aqueous, low-VOC rust preventives that give excellent performance and meet Californias new Rule 1144 limits.
2. Afton Chemicals Steve Anderson described promising research on new ester-based additives to replace medium-chain chlorinated paraffins.
3. John Belein of Quaker Chemical described alternatives to boron-based chemistries in machining and grinding fluids.
In addition, said Burke, other intriguing presentations included Oelheld on glass lubricants for forging; Germanys Institute of Material Sciences in Bremen on CoolArt, a new research and development program on fluids, and also on sensors to measure additive depletion.
Applications
Presentations in the applications track ranged from end users describing their fluid programs and their expectations to academics cutting edge research on measuring bacteria in fluids, said track chairman Greg Foltz of Milacron Marketing Co.
Boeing, Rolls Royce [University Technology Center in Manufacturing at the University of Nottingham] and ZF gave very good views on what fluid users expect, said Folz. Boeing described its U.S.-based metalworking fluid qualification process, while the Rolls Royce center in the U.K. outlined its evaluations of fluids for hard-to-cut metals. ZF spotlighted its huge savings since designing and adopting a primarily in-house fluid management program a decade ago.
Another highlight was Stefan Fennrichs method of using human blood in new tests of metalworking fluids and aerosols, to pinpoint human-specific reactions, Foltz noted. Fennrich is with University Hospital Tubingen in Germany.
Other key papers looked at Germanys standards for metalworking fluids, and contributed insights on microbial contamination of fluids, and how to identify microbial populations.
Regulations
Presentations on biocides and preservatives were highlights of the regulatory track, said chairman Paul Whitehead of WCA Environment Ltd. Several experts reported on the status of formaldehyde releasing biocides and on growing concerns with boric acid. And an update from Mike Morris [of Californias South Coast Air Quality Management District] showed the cooperation between regulators and industry to develop appropriate methodologies.
Global pressure on chemicals means we need global cooperation and coordination, Whitehead noted, singling out the proposal by Milacrons Eugene White for a global research consortium on metalworking fluids.
The 4th Symposium was an excellent continuation of previous symposia. It showed strong interest in Europe and opened doors to a wider audience, Whitehead concluded, agreeing with John Burke and Greg Foltz that there will be a need for a 5th Symposium to share the research and innovative programs that are being carried out around the world today.