Millions of workers engaged in manufacturing parts for products such as automobiles, farm equipment, aircraft, heavy machinery, and other hardware are exposed to metalworking fluids (MWFs). Metalworking fluids are in widespread, high volume use for their coolant, lubricant, and corrosion resistant properties during machining operations. These fluids are complex mixtures of oils, detergents, surfactants, biocides, lubricants, anti-corrosive agents, and other potentially toxic ingredients.

      Metalworking fluids/metal removal fluids are also called machining fluids, cutting fluids, and cutting oils. These fluids are those used in grinding, cutting, boring, drilling, and turning metal. Although metal removal fluids is a more specific term, these fluids are most often referred to by the generic term metalworking fluids.

      Industrial operations requiring the grinding, cutting, or boring of metal parts also require the use of metalworking fluids to meet productivity and quality requirements. Metalworking fluids have two primary functions: to cool and to lubricate.

      All metal removal processes generate a tremendous amount of heat. This heat must be reduced in order to achieve productivity and part quality. The cooling effect provided by a metalworking fluid gives the cutting tool or grinding wheel a longer life and helps to prevent burning and smoking. At the point where the tool is in contact with the part, lubrication is necessary to reduce friction between the tool and the part, resulting in improved tool life and better finishes on the metal cut.

      Metalworking fluids also provide corrosion protection for the newly machined part and machine tool. Water-miscible metalworking fluid formulations (those fluids that are meant to be diluted with water) include components that slow or prevent such corrosion. MWFs also help remove chips or swarf (an accumulation of fine metal and abrasive particles) from the cutting zone.

            There are four major classes of metal-working fluids widely available: straight oil, soluble oil, semisynthetic, and synthetic. Many metalworking fluids, except the straight oils, are mixed with...

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