Apr 02,2026
Cooling lubrication technology in mold processing: The secret to extending the life of knives
Cooling lubrication technology in mold processing: The secret to extending the life of knives
Cooling lubrication, Cutting fluid, MQL, Tool life, Machining efficiency
During the mechanical processing of molds (frainage, car cutting, drilling), intense friction between the blade and the piece generates a large amount of heat. If the heat is not removed in time, the blade will quickly wear out, the surface quality of the piece deteriorates, and even thermal deformation occurs. Cooling lubrication technology is precisely the key measure taken to control the cutting area temperature, reduce friction, extend the blade life, and improve processing efficiency.
The core roles of cooling lubrication include: 1 Cooling: Taking away cutting heat, reducing the temperature of blades and parts; 2 Lubrication: Forming a lubricating film between blades and sawdust, blades and parts, reducing friction and adhesion; 3 Scraping: High-pressure cutting fluid that washes sawdust away from the cutting area, preventing sawdust clogging; 4 Rustproofing: Protecting parts and machinery from corrosion.
There are many types of cutting fluids, and they need to be selected based on processing materials and processes. The most common is water-based cutting fluid (emulsified fluid, synthetic fluid), which has good cooling performance and low cost, suitable for most rough and semi-refined processing of cast steel. Oil-based cutting fluid lubrication performance is excellent, suitable for refining, threading, hinge holes, and other processes with high surface quality requirements. In recent years, micro lubrication (MQL) technology has become increasingly popular in order to protect the environment and reduce costs. MQL blends micro lubrication oil with compressed air to form a vapor that is sprayed to the cutting area, both achieving lubrication and producing almost no waste fluid, representing green processing.
The supply method of cutting fluid directly affects the effect. The traditional external cooling method (spraying from the outside through a nozzle) is simple, but the cooling fluid is difficult to penetrate deep into the cutting area. For deep-hole processing and high-speed cutting, the internal cooling method is often adopted, where the cutting fluid is sprayed directly onto the cutting blade through the main axle center, handle, and channels inside the blade, providing the best cooling effect. Modern digital-controlled machines are commonly equipped with a main axle center drain function, which in combination with dedicated internal cooling blades can increase blade life by more than 30%.
Maintenance and management of cutting fluids are not to be overlooked. Water-based cutting fluids, after use for a period of time, may deteriorate and stink due to bacterial proliferation, or their performance may decrease due to decreased concentration. Therefore, it is necessary to regularly check the concentration, pH value, bacterial content of cutting fluids, and supplement raw fluids or antiseptics. Scrap and oil stains in cutting fluids need to be removed promptly through the filtering system. Good maintenance not only ensures processing quality, but also extends the life of cutting fluids and reduces wastewater emissions.
The application of MQL technology is expanding. For high-speed milling and hard milling, MQL can provide sufficient lubrication while keeping the cutting area clean and easy to observe. MQL is especially suitable for processing sticky materials such as aluminum alloys and titanium alloys, which can effectively prevent granular tumors. However, MQL has higher requirements for the cleanliness and pressure stability of compressed air, requiring a dedicated generator and nozzle kit.
Dry cutting is the ultimate form of cooling lubrication. In some situations (such as cast iron processing, ultra-high-speed cutting), dry cutting can be achieved completely without the use of cutting fluid. This requires knife materials (such as CBN, ceramic) with extremely high red hardness, and a machine tool with a good waste disposal design. Dry cutting completely eliminates cutting fluid-related costs and environmental problems, and is one of the directions of green manufacturing.
Mastering cooling lubrication technology means being able to maximize knife life and processing efficiency while ensuring processing quality. It is not just a technical skill at the operating level, but also a core technology that process engineers must study in depth.
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