Volume 16 - Machining Part 5 docx

Fig. 22 Typical applications of PCBN tools with a lowered CBN content. Use of PCBN inserts (DBC50) in hardened steels (55 to 62 HRC). (a) Facing. (b) Copy turning. (c) Threading. (d) Grooving References 1. C. Phaal, Surface Studies of Diamond, Ind. Diamond Rev., No. 1965, p 486-489 2. A. Sawaoka, Boron Nitride: Structural Changes by Shock Compression and Preparation of Superhard Compacts by Very High Pressure Sintering, Ceram. Bull., Vol 62 (No. 12), 1983, p 1379 3. R. Berman and F. Simon, Z. Elektrochem., Vol 49 (No. 333), 1955 4. R.J. Wedlake, Technology of Diamond Growth, in The Properties of Diamond, J. Field, Ed., Academic Press, 1979 5. P.A. Bex and G.R. Shafto, The Influence of Temperature and Heating Time on PCD Performance, Ind. Diamond Rev., Vol 3, 1984, p 128-132 6. P. Herzig, Grinding Polycrystalline Diamond Tools, Ind. Diamond Rev., Vol 4, 1982, p 212-214 7. J.A. Pfluger, Automatic Grinding of PCD/PCBN Blanks, Ind. Diamond Rev., Vol 3, 1986, p 128-130 8. P.J. Heath and M.E. Aytacoglu, Edge Preparation of SYNDITE PCD and Parameters, Ind. Diamond Rev., Vol 3, 1984, p 133 9. P. Silveri, Shaping PCD Tools by Rotary EDM, Ind. Diamond Rev., Vol 3, 1986, p 108-109 10. P. Herzig, New Machine for Lapping the Table of PCD Inserts, Ind. Diamond Rev., Vol 3, 1983, p 134 11. P.J. Heath, "Structure Properties and Applications of Polycrystalline Cubic Boron Nitride," Paper presented at Superabrasives '85, New Developments in Diamond and CBN (Chicago), April 1985 12. A.G. Evans and D.B. Marshall, Wear Mechanisms in Ceramics, in Fundamentals of Friction and Wear of Materials, American Society for Metals, 1980, p 439-452 13. S. Herbert, SYNDITE Tools Reduce Downtime by 80:1, Ind. Diamond Rev., Vol 3, 1983, p 117-120 14. M. Wolf and R. Dreher, Machining of Aluminium Engine Parts for the Porsche 928, Ind. Diamond Rev., Vol 5, 1981, p 254-257 15. S. Herbert, Jaguar's Long Distance Runner, Ind. Diamond Rev., Vol 3, 1987, p 100-102 16. S. Herbert, Austin Rover's PCD Switch Pays Dividends, Ind. Diamond Rev., Vol 6, 1985, p 278-281 17. W. Hück, New Techniques in the Machining of Commutators, Ind. Diamond Rev., Vol 2, 1983, p 69-74 18. Diamond Composites Hit the Right Note, Ind. Diamond Rev., Vol 2, 1981, p 67 19. W. Stief, Tumpets Depend on Precision, Ind. Diamond Rev., Vol 3, 1987, p 112 20. E. Quadri, Finish Machining of Plastics, Ind. Diamond Rev., Vol 6, 1980, p 222 21. A Better Way to Machine Phenolics, Ind. Diamond Rev., Vol 4, 1982, p 215 22. G. Biastoch, Contact Lenses Machined With SYNDITE and Natural Diamond, Ind. Diamond Rev., Vol 2, 1983, p 66-68 23. F. Waltz, Machining Wood and Plastics With SYNDITE Tools, Ind. Diamond Rev., Vol 6, 1982, p 339-340 24. S. Herbert, Modern Insulation Materials A New Machining Approach, Ind. Diamond Rev., Vol 3, 1983, p 144-147 25. Roll Turning Using SYNDITE and AMBORITE Tools, Ind. Diamond Rev., Vol 6, 1984, p 334-340 26. S. Herbert, A Granite Machining Challenge Answered, Ind. Diamond Rev., Vol 4, 1984, p 199-201 27. G. Spur and V.E. Wunsch, Turning FRP With SYNDITE Test Results, Ind. Diamond Rev., Vol 4, 1985, p 195-199 28. W. Koglmeir, SYNDITE for Machining Fibre Glass Reinforced Epoxy Resin, Ind. Diamond Rev., Vol 11, 1978, p 395-397 29. A Better Way to Machine GRP Pipes, Ind. Diamond Rev., Vol 1, 1980, p 17 30. P. Schimmel, Economic Machining of GRP Laminates, Ind. Diamond Rev., Vol 6, 1982, p 348 31. B. Cullingworth, Syndite Helps Clinch Order, Ind. Diamond Rev., Vol 4, 1985, p 185 32. E. Heimbrand, Machining Composite Metals With PCD, Ind. Diamond Rev., Vol 4, 1985, p 187-190 33. Wood Products Latch Onto PCD, Ind. Diamond Rev., Vol 3, 1984, p 159-162 34. H. Lach, PCD Tools for Woodworking, Ind. Diamond Rev., Vol 4, 1985, p 166-167 35. H. Moitzi, PCD for Chipboard Machining, Ind. Diamond Rev., Vol 4, 1985, p 175-181 36. H. Schulz, Machining Wood Products With PCD, Ind. Diamond Rev., Vol 5, 1984, p 263-265 37. Elizabeth Ann's 100:1 Favourite, Ind. Diamond Rev., Vol 4, 1985, p 163-165 38. Diamond Tools in the Wood Products Industry, Ind. Diamond Rev., Vol 6, 1980, p 214-221 39. H. Prekwinkel, Woodworking With SYNDITE Tools, Ind. Diamond Rev., Vol 3, 1983, p 148-150 40. New Tools Ensure a Good Smoke, Ind. Diamond Rev., Vol 6, 1980, p 211 41. B. Cullingworth, SYNDITE's Potential in Tile Cutting, Ind. Diamond Rev., Vol 5, 1985, p 243 42. G. Ottevanger, Boring Sintered Carbide Rolls With SYNDITE PCD Tools, Ind. Diamond Rev., Vol 3, 1984, p 154-156 43. T.A. Notter and P.J. Heath, "The Selection of Machining Parameters Using AMBORITE," Paper presented at CSIR Second Seminar, Efficient Metal Forming and Machining (Pretoria, South Africa), Nov 1980 44. British Standard B.S. 4844: Part 2: 1972 Abrasion Resisting White Cast Irons, Part 2: Nickel- Chromium Grades 45. "AMBORITE Machining of Ni- HARD 2C (57HRC)," Leaflet T14.1, De Beers Industrial Diamond Division (Pty) Ltd. 46. S. Herbert and P.J. Heath, AMBORITE; an Answer to the Ni-HARD Machining Problem, Ind. Diamond Rev., Vol 2, 1981, p 53-56 47. C. Stevens, A Bold Tooling Investment Brings 40% Productivity Increase, Ind. Diamond Rev., Vol 3, 1982, p 130-134 48. H. Muller and K. Steinmetz, Machining Mineral Crushing Rings With AMBORITE, Ind. Diamond Rev., Vol 1, 1983, p 30-33 49. G. Johnson, Machining in Half the Time, Ind. Diamond Rev., Vol 6, 1985, p 309-310 50. Milling of Ni-HARD 2C, Ind. Diamond Rev., Vol 6, 1983, p 305 51. M.O. Nicolls, Machining Ni-HARD Augers with AMBORITE, Ind. Diamond Rev., Vol 1, 1984, p 28-29 52. S. Herbert, New Potential in the Heavy Machine Shop, Ind. Diamond Rev., Vol 6, 1984, p 307-309 53. P. Silveri, Pump Producer Goes for AMBORITE, Ind. Diamond Rev., Vol 6, 1985, p 287-288 54. F.W. Mansfeld, Turning of Chill Cast Rolls on CNC Production Machines, Ind. Prod. Eng., Vol 1, 198 2, p 69 55. S. Herbert, AMBORITE Cuts Machining Time in Mill Roll Reclamation, Ind. Diamond Rev., Vol 5, 1981, p 258-260 56. S. Herbert, Roll Machining Costs Reduced, Ind. Diamond Rev., Vol 3, 1982, p 140-141 57. S. Herbert, High Speed Threading in Parent Hard Metal, Ind. Diamond Rev., Vol 1, 1986, p 19-21 58. B. Cullingworth, Seven Times Cheaper With AMBORITE, Ind. Diamond Rev., Vol 4, 1984, p 195 59. S. Herbert, Cycle Times Reduced by 90% in Re-machining of Thread Rolls, Ind. Diamond Rev., Vol 4, 1981, p 176-178 60. G. Werner and W. Knappert, Machining Hardened Bearing Races With PCBN, Ind. Diamond Rev., Vol 3, 1985, p 117-120 61. W. Konig and T. Wand, Turning Bearing Steel With AMBORITE and Ceramic, Ind. Diamond Rev., Vol 3, 1987, p 117-120 62. P. Fitton, Machining Hard-Faced Components Better Economics Are Possible, Ind. Diamond Rev., Vol 6, 1984, p 310-312 63. Machining of Cast Iron, in Machining, Vol 3, 8th ed., Metals Handbook, American Society for Metals, 1967, p 333-352 64. D.K. Aspinwall and W. Chen, Machining of Grey Cast Iron Using Advanced Ceramic Tool Materials, to be published 65. E. Lurger, J. Steber, V. Frommberz, et al., Machining of Cylinder Bores at BMW, Ind. Diamond Rev., Vol 3, 1982, p 135 66. K. Sanger and K. Steinmetz, No Putting the Brakes on AMBORITE, Ind.Diamond Rev., Vol 6, 1982, p 350- 355 67. J. James, A Bed-Time Story From Harrison, Ind. Diamond Rev., Vol 3, 1985, p 113-115 68. J. Shanks, AMBORITE Saves the Day, Ind. Diamond Rev., Vol 3, 1983, p 133 69. Milling Meehanite With AMBORITE, Ind. Diamond Rev., Vol 4, 1981, p 179 Metal Cutting and Grinding Fluids Elliot S. Nachtman, Tower Oil & Technology Company Introduction METAL CUTTING AND GRINDING OPERATIONS involve a complex set of operating parameters, and the choice and effectiveness of a cutting or grinding fluid are determined by: • The design, rigidity, and operating condition of the machine tool • The speed, feed, and depth of cut • The composition, finish, and geometry of the cutting tool • The mode of fluid application • The geometry of the material to be machined • Surface coatings • The composition, microstructure, and residual stress distribution in the workpiece When properly applied, cutting fluids can increase productivity and reduce costs by making possible the use of higher cutting speeds, higher feed rates, and greater depths of cut. The effective application of cutting fluids can also lengthen tool life, decrease surface roughness, increase dimensional accuracy, and decrease the amount of power consumed as compared to cutting dry. Knowledge of cutting fluid functions, types, physical limitations, and composition plays an important role in the selection and application of the proper fluid for a specific machining situation. The functions, chemistry, control, application, recycling, and disposal of cutting fluids will be discussed in this article. The health implications and biology of cutting fluids will also be discussed. Functions of Cutting and Grinding Fluids Depending on the machining operation being performed, a cutting or grinding fluid has one or more of the following functions: • Cooling the tool, workpiece, and chip • Lubricating (reducing friction and minimizing erosion on the tool) • Controlling built-up edge on the tool • Flushing away chips • Protecting the workpiece tooling and machine from corrosion The relative importance of each of these functions depends on the work material, the cutting or grinding tool, the machining conditions, and the finish required on the part. Grinding fluids perform several of the same functions as cutting fluids. Grinding fluids lubricate the grit/workpiece interface, thus reducing the generated heat and the power requirements for a given material removal rate. The primary difference between the functions of grinding and cutting fluids is that lubrication is more important in grinding than in cutting. In metal cutting, most of the heat generated during the cutting operation is carried away in the chip. Relatively less heat is generated in the workpiece and the tool. In the case of grinding, however, most of the heat is retained in the workpiece. Therefore, lubrication becomes more important for grinding fluids than for cutting fluids. Cutting Fluids. Two functions of cutting fluids include lubrication and cooling so that the frictional forces and temperature are reduced at the tool/workpiece interface. In high-speed cutting operations, the cooling provided by the cutting fluid is its most important function. At moderate cutting speeds both cooling and lubrication are important, but at low speeds, lubrication becomes the dominant function of a cutting fluid. Chip formation and built-up edges are related to the frictional effects of metal cutting. Figure 1 shows a schematic of the cutting operation with a single-point tool. A tool moving with a velocity V and a depth of cut t o creates a chip of thickness t c that is greater than t o . The chip is generated at a shear plane that makes an angle with the direction of cut. This angle, known as the rake angle, is an important variable in the mechanics of chip formation. The relief, or clearance, angle is also important because it provides potential access to the cutting zone for lubrication. Fig. 1 Schematic of the cutting process with a single-point tool. Source: Ref 1 In considering the potential for improving the cutting process with a cutting fluid, Fig. 2 illustrates the major areas of deformation and friction that occur during the generation of chips. In Fig. 2, zone 1 indicates the area of strain hardening that forms in the material being cut ahead of the tool. Microcracking can take place in the zone, and relatively high temperatures result from the deformation and resultant strain hardening. In zone 2, the deformed chip moves out of the shear zone and flows up the surface of the tool. As the chip slides up the face of the rake of the tool, it generates more heat as a result of friction between the chip and the tool. In zone 3, as the tool traverses the freshly cut surface, further rubbing of the tool against the workpiece material takes place, thus generating friction and additional deformation. As chip formation proceeds, the tool edge forms a built-up edge (zone 4), which creates more local plastic deformation and friction. In zone 5, below the area of primary metal removal, additional plastic deformation takes place, along with some strain hardening. The geometry of the chips varies with the workpiece material and the cutting conditions. The various types of chips are illustrated in Fig. 3. Fig. 2 Zones of deformation and friction in chip formation. Source: Ref 2 Fig. 3 Types of chips obtained in metal cutting. (a) Continuous chip. (b) Continuous chip with a secondary shear zone. (c) Continuous chip with a large primary shear zone. (d) Built- up edge in a continuous chip. (e) Inhomogeneous (serrated) continuous chip with regions of low and high shear in the primary zone. (f) Discontinuous chip. Source: Ref 1 Lubrication. Cutting fluids improve tool life and allow higher cutting speeds by reducing the amount of friction that occurs during the cutting process. Cutting fluids with good lubricating qualities can also: • Allow the formation of a cont inuous chip when low cutting speeds result in the formation of discontinuous chips or serrated continuous chips (Fig. 3) • Reduce the frictional forces between the tool and the rake face • Reduce the size of the built-up edge or in some cases eliminate built- up edge formation. Total elimination of the built-up edge will produce a superior finish on the part being machined a nd will result in less frictional drag on the flank face • Reduce adhesive wear by reducing adhesion between the tool and the chip or the workpiece • Produce insignificant lubricant effects in the case of extremely brittle materials that yield very small discontinuous chips Cooling. Cutting fluids reduce the temperature of the metal cutting operation by transferring heat away from the workpiece and the tool. Some of the factors involved in cooling are as follows: • Cooling effects due to the application of t he cutting fluid increase the shear strength of the material being cut, thus increasing the forces required for metal cutting. Generally, this effect is small for most metals • The cooling effects of cutting fluids may be deleterious if the change in temper ature caused in the cutting tool is abrupt and discontinuous. Abrupt changes in temperature may cause fracture and spalling of the tool; ceramic tooling is particularly sensitive in this regard • The cooling from cutting fluids is generally related to their thermal properties. In general, cooling efficiency is less for an oil than for an emulsion and is greatest with a water solution. Frictional effects, however, may complicate this relationship because the lubricating properties influence the amount of heat generated • Cooling efficiency can be reduced by the heat transfer characteristics of high- viscosity fluids. High cutting speeds can initially improve the cooling because the viscosity of the cutting fluid decreases with temperature, but beyond a certain temperature this beneficial effect on cooling is no longer present • The effectiveness of cooling depends on the amount of surface wetting, fluid viscosity, chemical reactivity and molecular size, and the physical characteristics of fluid flow Chemistry of Cutting and Grinding Fluids Metal cutting and grinding fluids are of two general types: solutions and emulsions. Solutions consists of a base fluid such as petroleum oil, a petroleum solvent, a synthetic fluid, or water. These base fluids can then be formulated with various additives that are soluble in the fluid. Emulsions, on the other hand, are composed of two phases: a continuous phase consisting of water, and a discontinuous phase consisting of small particles of oil, petroleum, or synthetic fluid suspended in the water. These emulsions are commonly called soluble oils. Oil or synthetic solutions generally have the highest lubricating capabilities and the lowest cooling efficiencies. Water- base solutions, on the other hand, have the highest cooling efficiencies and lower lubrication effectiveness. In general, emulsions tend to have moderate properties for both cooling and lubrication. Solutions. Some cutting and grinding solutions are described below with regard to three types of base fluid. In all metal cutting and grinding solutions, additives are selected that are soluble or in some cases dispersible in the fluid. In combination, the fluid and the additive display the desired properties. Cutting Oils. The so-called cutting or grinding oils have either a naphthenic or paraffinic oil or a petroleum solvent as the primary ingredient. Paraffinic mineral oils differ from naphthenic base oils in two ways. First, paraffinic oils have a much higher concentration of straight-chain carbon atoms varying greatly in length, and second, they have a smaller concentration of ring compounds, such as naphthenic and polycyclic aromatic compounds. Paraffinic oils exhibit greater oxidation resistance than naphthenic oils and tend to maintain their viscosity over a wider temperature range. On the other hand, naphthenic oils tend to form more stable solutions of additives than the paraffinic oils. In naphthenic oils, the aromatics in the oil are surface active and therefore provide improved load-carrying capacity. All mineral oils contain a large variety of ring and straight-chain compounds of varying molecular weight. Some of these typical structures are illustrated in Fig. 4. Fig. 4 Some components of mineral oil Synthetic fluid lubricants have a controlled molecular structure with predictable properties. Synthesized hydrocarbons such as the polyalphaolefins have been used to replace mineral oil in some special cutting fluid applications. Long-chain alcohols have also been used for special applications. However, a significant market has not developed for these synthetic cutting fluids. Water-base solutions are often termed "synthetics" in industry. Water-base solutions have excellent heat transfer characteristics because of the high heat capacity of water. However, the purity of the water can significantly affect the performance of water-base cutting fluid solutions. Biological attack, foaming, additive displacement, and deposit formation are some consequences of mineral concentrations or other impurities that may be present in the water. Emulsions consist of immiscible fluids that form a relatively stable mixture because of emulsifiers or surface-active chemicals (which are soluble in the fluids). Emulsions for metal cutting and grinding fluids consist primarily of a continuous phase of water containing suspended mineral oil or synthetic fluid. The particle size of the suspended fluid varies and depends on the effectiveness of the surfactant chemicals used to emulsify the system. Clear emulsions can be produced when the suspended phase consists of sufficiently fine particle sizes, but in most cases emulsions have a milky- white or blue-white color, depending on the chemistry of the additives. In these cases, the particle size is larger. In general, when suitable surfactants are added to a pair of immiscible liquids such as oil and water, the surfactants will be absorbed at the interface between the two liquids. The hydrophilic group, that is, the part of the molecule of the surfactant that is water soluble, will orient itself so as to become part of the water phase, and the lipophilic or oil-miscible portion of the molecule will orient itself so as to become part of the oil phase. A large number of surfactants are available for use in promoting the development of a stable emulsion. In general, combinations of emulsifiers or surfactants are used. Soaps of long-chain fatty acids, phosphate esters, sulfonates, and ethoxylated alcohols are frequently used in appropriate ratios as components of the emulsion-surfactant system. The stability of emulsions is important in metal cutting and grinding operations, and the destabilization of an emulsion is to be avoided. Destabilization often occurs because of the buildup of minerals from frequent additions of impure water and the buildup of swarf from the machining operation. The inadvertent addition of cleaners or dirt may also break the emulsion. Splitting of the emulsion, when it occurs, generally results in the formation of two distinct liquids: water and the oil floating at the top. However, a phenomenon known as creaming may also occur, which produces a thick cream layer that floats on the surface. This layer is not so much a result of the breaking of the emulsion but rather is the product of two separate emulsions being created. The emulsion at the top has a much higher concentration of suspended oil particles. The presence of the cream may indicate that a process of breaking of the emulsion is about to begin. On the other hand, such mixtures may be advantageous in some metal cutting operations. Typical stages in the breaking of emulsions are illustrated in Fig. 5. Fig. 5 Instability in emulsions. Source: Ref 3 Additives. Some of the important classes of additives used in both solutions and emulsions are described below. Extreme-Pressure (EP) Additives. These chemical compounds vary in structure and composition and are sufficiently reactive with the metals being machined to form relatively weak compounds at the tool/workpiece interface. Extreme-pressure additives serve as solid lubricants with low binding energy and therefore reduce the friction between the tool and the workpiece. They are primarily sulfurous additives (such as sulfurized esters of fatty acids), chloride additives (such as chlorinated hydrocarbons or chlorinated esters), or phosphorous additives (such as phosphoric acid esters). Solid lubricants such as molybdenum disulfide have also been used in small amounts. These solid lubricants deposit on the metallic surface and reduce the friction between the tool and the workpiece. Borates have been added for the same purpose. However, organic molecules with sulfur and chlorine are by far the most widely used EP additives. The chemical reactions that occur during the formation of sulfides and/or chlorides as a result of workpiece-additive interaction are very complex and not clearly understood. Detergents. Compounds such as long-chain alcohols, substituted benzene sulfonic acid, and petroleum sulfonic acids can reduce or prevent deposit formation on the workpiece. Antimisting Additives. Airborne contamination by the metal cutting fluid in the plant is a long-standing problem that occurs when oil-base solutions are used. The addition of small quantities of acrylates or polybutanes will reduce mist formation by encouraging the buildup of larger particle sizes, which are heavier and much less readily airborne. Antifoaming Additives. Foaming generally occurs when agitation from either the cutting operation or fluid handling introduces air into the fluid. To prevent or minimize the formation of foam, the free energy of the film surface must be reduced. Antifoaming agents have been developed for this purpose. Polyalkoxysiloxanes, fumed silica, high molecular weight amides, and polyglycols are effective in specific metal cutting fluids. Odor Masks. High temperatures at the tool/workpiece interface heat the fluid and often result in odors that are disagreeable to the operator. Pine oil, cedar oil, and sassafras essence have been used to mask these odors, thus making the fluid more acceptable in long-term operations. Corrosion Inhibitors. The corrosion of machine parts and the machine tool can be a problem, particularly with water- base fluids. Sulfonates, borates, and benzotriazoles have been used as additives in cutting fluids to help prevent corrosion. Many organic amines and sulforates, which provide corrosion protection, may serve another purpose that of providing effective surfactant characteristics as well as corrosion protection. In the case of copper alloys, toluyltriazole is an effective inhibitor. Dyes. Both oil- and water-soluble dyes are used to assist in the identification of the metalworking fluid and to help in identifying the location of the fluid with respect to the application technique. Antimicrobial Agents. Microbial growth will take place in cutting fluids that intentionally or inadvertently contain water. Bacteria, fungi, and/or mold will grow, depending on the growth conditions and the competition for nourishment among these organisms. Sulfate-reducing bacteria produce the well-known "Monday morning stink." These microbes do not require air, and they grow at the bottoms of sumps, attacking the sulfur in EP additives or the sulfur incidentally present in a cutting oil. This produces malodorous complex sulfur compounds. A number of biocides are available for use in attacking and killing bacteria, mold, and fungi. Table 1 lists biocide manufacturers, the active ingredients of the biocides, and other pertinent information. [...]... Fluid flow L/min 20 gal./min 5 132 170 227 35 45 60 19/tool Up to 227/tool 5/ tool Up to 60/tool 7-1 1 0.3 to 0.43 × diam, mm 2-3 2-3 × diam, in 7-2 3 2 0-6 5 4 0-1 50 6 4-1 90 2-6 5- 1 7 1 0-4 0 1 7 -5 0 2 0-3 0 3 0-9 8 5- 8 8-2 6 1 9-3 0 mm (0.7 5- 1 .18 in.) diameter 3 0-6 0 mm (1.1 8-2 .38 in.) diameter Trepanning External chip removal heads 5 0-9 0 mm ( 2-3 .5 in.) diameter 9 0-1 50 mm (3. 5- 6 in.) diameter 15 0-2 00 mm (6.8 in.) diameter... heads 6 0-1 50 mm (2.3 7-6 in.) diameter 15 0-3 00 mm ( 6-1 2 in.) diameter 30 0-4 60 mm (1 2-1 8 in.) diameter 46 0-6 10 mm (1 8-2 4 in.) diameter Honing Small Large Broaching Small Large Centerless grinding Small Large Other grinding 9 8-2 50 25 0-4 90 2 6-6 6 6 6-1 30 3 0-1 80 6 1-3 00 12 0-3 94 8-4 8 1 6- 80 3 2-1 04 41 5- 8 14 81 4-1 300 130 0-1 740 174 0- 2160 11 0-2 15 21 5- 3 40 34 0-4 60 46 0 -5 70 10/hole 20/hole 3/hole 5/ hole 40/stroke 0. 45/ stroke... number 27 1-3 0 27 1-2 6 27 1-1 8 10,00 0-1 Zinc omadine: zinc 2-pyridinethiol-l-oxide; powder 95% , aqueous dispersion 48% Sodium omadine: sodium 2 pyridinethiol-l-oxide; powder 90%, aqueous solution 40% 0.0079 0.0 15 0.0 05 0.01 15 1 25 8-8 40 1 25 8-8 41 1 25 8-8 42 1 25 8-8 43 Triadine 10: hexahydro-1,3 , 5- tris (2-hydroxyethyl)s-triazine 63.6%, sodium 2-pyridinethiol-l-oxide 6.4% Kathon 886 MW: 5- chloro-2-methyl-4 isothiazolin3-one... isothiazolin3-one 8.6%; 2-methyl-4-isothiazolin-3-one 2.6% 0.07 in synthetic fluids or 0.1 in oil-containing fluids 1 25 8-9 90 0.002 5- 0 .01 25 70 7-1 29 Vancide TH: hexahydro-1,3 , 5- triethyl-s-triazine 95% Vancide 51 : sodium dimethyldithiocarbamate 27.6% 0.0 5- 0 .1 196 5- 5 5 4% in water as bactericide; 196 5- 8 This product is marketed as Grotan in the United States Comments Good oil solubility; stable in oil-water emulsion... O5d Alloy steels E2c, O5c, d; O7c O4c, O5c E2c, O5c Stainless steels S2c, O3c, O5c O5c E2d, S2c, O4d, O5d E2d, S2c, d; O4d E2c, S2c, O3c, O5c E2c, S2c, O3c Tool steels E2c, S2c, O4c, O5c O4c, O5c E2c, O5c, O6d E2c, O5c E2c, S2c, O4c, O5c E2d, S2d, O4d, O5d E2c, S2c, O3c, O5c E2c; O5c, d E2c, S2c, O3c Free -machining low-carbon steels E2d, O4d, O5d E2d, O4d Cast irons E1c, E2c, S1c, S2c E2c, S2c, O5c... diameter 50 mm (2 in.) diameter 75 mm (3 in.) diameter Milling Small cutters Large cutters Drilling, reaming 25 mm (1 in.) diameter Drilling, large Gundrilling External chip removal type 4. 6-9 .4 mm (0.1 8-0 .37 in.) diameter 9. 4-1 9 mm (0.3 7-0 . 75 in.) diameter 1 9-3 2 mm (0.7 5- 1 . 25 in.) diameter 3 2-3 8 mm (1.2 5- 1 .50 in.) diameter Internal chip removal type 7. 9-9 .4 mm (0.3 1-0 .37 in.) diameter 9. 4-1 9 mm (0.3 7-0 . 75. .. Bioban P-1487: 4-( 2-nitrobutyl)-morpholine 70%; 4,4 '-( 2-ethyl-2-nitrotrimethylene) dimorpholine 20% Tris Nitro: tris(hydroxymethyl) nitromethane; aqueous 50 %, powder 100% Grotan BK(a): hexahydro-1,3 , 5- tris (2-hydroxyethyl)s-trizane 78% 0.0 1-0 .3 Lehn & Fink Industrial Products, Division of Sterling Drug Inc Olin Corporation Rohm and Haas Company R T Vanderbilt Company, Inc (a) 0.2 0.1 powder 0. 15 aqueous... O5c O5c O5c E2c, O4c E2c; O5c, d O4c, O5c S2c, O5c, O7c E2c, S2c E2c, O3c E1d, E2d, S1d, S2d, O6d E2c, S2c, O6d E2d, O1, O4d E2d, S2d, O1 E2d, S2d Material (a) E2c, d; S2c, d E2c, S2c, O3c E2c, S2c, O5c E2c, S2c, O5c E2c, S2c, O5c E2c, d E2c, d; S2c, d; O6d E2c, d; S2c, d; O6d E2c, S2c, O5c, O7c S2c,O5c E2c, S2c, O5c E1d, E2d, S1c, S2c Surface, cylindrical, and centerless grinding E2c, d; S2c, d; O5c... d; O5c E2c, d; S2c, d; O5c E2c, S2c, d; O5c E1c, d; S1c, d; O4d E2c, d; S2c, d; O5c E2c, d; S2c, d E2d, S2d Crash and form grinding O3c, O5c E2c, d; O3d, O5d O4d, O5d O4d, O5d O4d, O5d E2c, O5d E2d, S2d E2c, d; O6d, O7d E2d, S2d E2d, S2d E2d, O4d E2d, S2d E1c, d; S1c, d; O4d E1d, E2d, S1d, S2d E2c, d; S2c, d O3c, O5c E1d, E2d, S1d, S2d E, emulsions: 1, surface active; 2, extreme-pressure S, solution:... under the U.S Federal Hazardous Substances Acts These animal tests consist of: • • • • • Acute oral toxicity: 16 CFR 150 0.3 (C) (1 and 2) Acute inhalation toxicity: 16 CFR 150 0.3 (C) (1 and 2) Acute dermal toxicity: 16 CFR 150 0.40 Primary skin irritation: 16 CFR 150 0.41 Acute eye irritation: 16 CFR 150 0.42 There is a great deal of uncertainty about the relationship between these test results and human health . mm (0.3 7-0 . 75 in.) diameter 2 0-6 5 5- 1 7 1 9-3 2 mm (0.7 5- 1 . 25 in.) diameter 4 0-1 50 1 0-4 0 3 2-3 8 mm (1.2 5- 1 .50 in.) diameter 6 4-1 90 1 7 -5 0 Internal chip removal type 7. 9-9 .4 mm (0.3 1-0 .37 in.). heads 5 0-9 0 mm ( 2-3 .5 in.) diameter 3 0-1 80 8-4 8 9 0-1 50 mm (3. 5- 6 in.) diameter 6 1-3 00 1 6- 80 15 0-2 00 mm (6.8 in.) diameter 12 0-3 94 3 2-1 04 Internal chip removal heads 6 0-1 50 mm (2.3 7-6 in.). in.) diameter 41 5- 8 14 11 0-2 15 15 0-3 00 mm ( 6-1 2 in.) diameter 81 4-1 300 21 5- 3 40 30 0-4 60 mm (1 2-1 8 in.) diameter 130 0-1 740 34 0-4 60 46 0-6 10 mm (1 8-2 4 in.) diameter 174 0- 2160 46 0 -5 70 Honing