ILMA Compoundings September 2016 - 24

VOICES & VIEWS Controlling Foam in Metalworking Fluids: The Great Balancing Act Monica A. Ford, Ph.D. It's thick and frothy, but as you look closer you realize it's thousands of little bubbles waiting to burst into problems in your metalworking fluid formulation. It's the dreaded foam. F oam is one of the most commonly encountered problems when using certain types of metalworking fluids (MWFs). MWFs are often used in high-energy applications, where they are applied through narrow spray nozzles at high speeds. Unfortunately, these conditions are optimal for generation of foam, especially in formulations containing emulsifiers and other surface-active components. The presence of foam can be harmful, as foam has no lubrication or cooling capacity and can lead to damage of pumps and metal parts. Metalworking fluids are designed to provide a few important functions, two of which are lubrication (typically through an oil phase with specialty additives) and cooling (typically through an aqueous phase). You've probably heard the saying "Oil and water don't mix." That's where emulsifiers come in to bridge the gap. Formulators use emulsifiers as additives to create fluids that provide the benefits of both oil (lubrication) and water (cooling) in a single system. While these additives are necessary, they come with challenges - they can stabilize the dreaded foam. Therefore, in order to control foam in MWF applications, a great balancing act must be performed. is being circulated over a given time. It is beneficial to utilize formulations that have been designed to work optimally in the operations in which they will be used. Ideally, end-users of MWFs are encouraged to work with their MWF supplier to identify the best fluid for a given operation. The MWF supplier takes a number of factors into account when selecting an MWF formulation to use in a specific type of operation. Some of the factors that should be considered are: * MWF type Semisynthetic formulations tend to have a higher foaming tendency than emulsifiable oil formulations, which subsequently tend to have higher foaming tendency than synthetic MWF formulations. When possible, in operations that use MWFs at high pressures and high volumes, simply changing the type of MWF may significantly help in controlling foam problems. Changing the volume of oil in the MWF is another useful tool for controlling the level of foam in a metalworking application, as higher oil formulations tend to show less foaming than "low oil" formulations. It's important to note that there are many factors that contribute to foam problems in a metalworking operation. Some of these factors are fluid formulation issues, contamination issues, operating issues such as sump level, clogged flow, etc. This article will focus on issues related to fluid formulation. Metalworking fluids are utilized across a range of operations, which have different levels of intensity under which the MWF is applied. For example, some high-energy operations, such as grinding and high-speed milling, are more prone to result in foam generation from the speed and volume of MWF that Vol. 66 No. 9 * 24 * September 2016 Compoundings

Table of Contents for the Digital Edition of ILMA Compoundings September 2016

FROM THE CEO
BOARD BRIEF
NOTES FROM MSCI
THE HEART OF ILMA
THE ARGUS ANALYSIS
VOICES & VIEWS
INTERNATIONAL INSIGHT
SPEAKER SPOTLIGHT
FAMILY BUSINESS
FINANCIAL FREEDOM
RULES & REGS
POWER PLAY
LEGAL EASE
THE WHITE PAPER
ADVERTISERS INDEX
ILMA Compoundings September 2016 - 1
ILMA Compoundings September 2016 - 2
ILMA Compoundings September 2016 - 3
ILMA Compoundings September 2016 - 4
ILMA Compoundings September 2016 - FROM THE CEO
ILMA Compoundings September 2016 - 6
ILMA Compoundings September 2016 - 7
ILMA Compoundings September 2016 - 8
ILMA Compoundings September 2016 - BOARD BRIEF
ILMA Compoundings September 2016 - 10
ILMA Compoundings September 2016 - 11
ILMA Compoundings September 2016 - 12
ILMA Compoundings September 2016 - NOTES FROM MSCI
ILMA Compoundings September 2016 - 14
ILMA Compoundings September 2016 - THE HEART OF ILMA
ILMA Compoundings September 2016 - 16
ILMA Compoundings September 2016 - 17
ILMA Compoundings September 2016 - 18
ILMA Compoundings September 2016 - 19
ILMA Compoundings September 2016 - 20
ILMA Compoundings September 2016 - THE ARGUS ANALYSIS
ILMA Compoundings September 2016 - 22
ILMA Compoundings September 2016 - 23
ILMA Compoundings September 2016 - VOICES & VIEWS
ILMA Compoundings September 2016 - 25
ILMA Compoundings September 2016 - INTERNATIONAL INSIGHT
ILMA Compoundings September 2016 - 27
ILMA Compoundings September 2016 - SPEAKER SPOTLIGHT
ILMA Compoundings September 2016 - 29
ILMA Compoundings September 2016 - FAMILY BUSINESS
ILMA Compoundings September 2016 - 31
ILMA Compoundings September 2016 - FINANCIAL FREEDOM
ILMA Compoundings September 2016 - 33
ILMA Compoundings September 2016 - RULES & REGS
ILMA Compoundings September 2016 - 35
ILMA Compoundings September 2016 - POWER PLAY
ILMA Compoundings September 2016 - 37
ILMA Compoundings September 2016 - LEGAL EASE
ILMA Compoundings September 2016 - 39
ILMA Compoundings September 2016 - THE WHITE PAPER
ILMA Compoundings September 2016 - 41
ILMA Compoundings September 2016 - ADVERTISERS INDEX
ILMA Compoundings September 2016 - 43
ILMA Compoundings September 2016 - 44
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