Development of methodology for monitoring of metalworking fluids quality

Efficient monitoring of metal-working fluids (MWFs) is crucial to maintaining optimal machining performance and ensuring the safety and health of workers in the metalworking industries. Knowledge of the performance of cutting fluids in the machining of various workpiece materials is very important to improve the efficiency of any machining process. Metal machining companies using MWS have the opportunity to choose the best product from the wide range offered, which can differ in physical parameters as it is designed to be best for the selected process. The unique adaptation to the manufacturing process poses certain challenges in monitoring MWS quality during machining. The importance of MWS quality is crucial, which can lead to costly defects and loss of workpieces. The monitoring only by the quality lab sometimes is insufficient. This article presents the development of a sensor for the indirect monitoring of MWFs, aiming to provide a cost-effective and nonintrusive solution to assess the quality and condition of these fluids. The measurement results are compared with those of other emulsion quality control protocols. Its implementation can significantly enhance the efficiency of MWF management, leading to improved machining performance, reduced downtime, and enhanced worker safety. The sensor's nonintrusive nature eliminates the need for frequent manual sampling, reducing costs and minimizing the environmental impact associated with traditional monitoring practices. Overall, the sensor described in this article offers a viable solution for indirect monitoring of MWFs, contributing to the advancement of smart manufacturing and the optimization of metalworking processes.