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2013 AM Education Course Description: MWF 250 - Troubleshooting

December 01, 2012

Annual Meeting
STLE University

Education Course Fact Sheet: Metalworking Fluids 250: Understanding & Controlling Metal Removal Fluid Failure

Course content, instructors and details subject to change. This listing was last updated on March 1, 2013.

Date/Time: Wednesday, May 8, 2013, starting at 8:00 a.m. For details, see course agenda

Course Chair: Dr. Fred Passman, BCA, Inc.

Course Description: Once a metalworking fluid (MWF) has been qualified for use in an application, its performance depends on successful fluid management.  In turn, successful fluid management depends on a fundamental understanding of the factors that work against fluid life and fluid performance, as well as cost effective strategies for preventing these factors from causing MWF failure.  MWF 250 is designed to meet both of these needs.  It covers primary failure mechanisms, including: the effect of contaminant particle size, water quality, microbes and oil contamination.  It also presents recommendations on how best to prevent each of these factors from destroying MWF performance and shorting MWF functional life.  The instructor team is made of internationally recognized experts who have an average of more than 30 years MWF management experience.   This course is designed for those involved in developing, working with and using metalworking fluids.

You may also like: MWF 105 - Metal Forming Fluids, to be held before this course on Sunday.


COURSE MODULES

Introduction

Overview: This module will provide a brief overview of how and why the fluid failure mechanisms addressed in this course were selected.  We’ll also discuss how this course fits in with STLE’s Metalworking Fluid Management Training Program which now includes five metalworking fluid management courses.

Instructor: Fred Passman, BCA, Inc.

Biography: Dr. Passman is an STLE Fellow and Certified Metalworking Fluids Specialist with 35 years’ experience in environmental-industrial microbiology. Since 1973, Dr. Passman has conducted research and consulted to government and private industry on topics as diverse as composting municipal sewage sludge, U.S. EPA criteria for various groups of toxic substances in fresh-water systems, microbially enhanced oil recovery, and microbial contamination control in industrial process-fluids.  He is a member of numerous professional and trade organizations including ASTM and STLE. Within STLE, he is currently the Chair of the Education and Certification Harmonization Ad Hoc Committee. Dr. Passman is Chair of ASTM Subcommittee E.34.50 Health and Safety of Metalworking Fluids, Vice-chair of ASTM Committee E34 Occupational Health and Safety and is an active member of E.35.15 Antimicrobial Pesticides. He has drafted ASTM Standards for each of these committees.  Dr. Passman has twice received STLE’s Wilber Deutsch Memorial Award for writing excellence, and is a recipient of STLE’s P.M. Ku Award.  He has more than 40 publications to his name.

Metal Worked and Particle Size Considerations

Overview: The type of metal being machined can significantly affect the stability of contain types of metalworking fluids. The accepted cause is that certain metals have three positive charges while some metals have two positive charges. In addition some metal working processes generate very small particles, while other processes generate long string-like chips. The smaller particle size generates more surface area per mass of metal removed and thus the available reactive surfaces of the metal increases.

Instructor: John Burke, Houghton International

Biography: John Burke is the Global Director of Engineering Services for Houghton International.  He received his engineering degree from the University of Dayton in 1971. He has 41 years of experience in the metalworking industry, and has five U.S. patents. John has been an instructor for STLE’s Metalworking Fluid Education Course for the past 21 years.. John is a Certified Metalworking Fluid Specialist . John became a Fellow in STLE in 2011. He received the P. M. Ku Award from STLE in 2006. John received an award from President George Bush at the White House in 1991 for advances in waste minimization.

Filtration, Gravity, Vacuum or Pressure

Overview: Filtration of metalworking coolants has a major effect on the quality of the finished product and life of the coolant itself. This module will discuss the different filter barriers, disposable media and non-disposable media systems, system operation covering different styles of separation and filtration for metalworking coolants; with their individual characteristics and performance levels, and a discussion about cost versus performance for differing systems and customer requirements or expectations.

Instructor: Dave Hanney, Durr EcoClean

Biography: Dave Hanney is the Applications and Product Manager for Durr Ecoclean Inc. Filtration Division (Formerly Henry Filters Inc.) since July 2007. He has been with the Durr Ecoclean GmbH group for over (30) years, previously serving as Managing Director for the United Kingdom's branch of Durr Ecoclean Filtration Division; which from 1985 served the complete European Automotive, Aerospace and general markets coolant filtrations needs. He received degree's in the United Kingdom covering Mechanical Equipment design and Production Handling techniques, and relocated to Bowling Green; Ohio to focus on the development of new filtration systems for the world markets.

Water Quality Issues and Control Practices

Overview: Water comprises 90-95% of most water-based metalworking fluid mixes. The quality of the water is therefore critical to the performance of the fluid. Sources of water, effects of the mineral content, measurement methods of various ions, and water treatment methods will be presented in this module.

Instructor: Gary Rodak, Machining Efficiencies, Inc.

Biography: Gary Rodak, president of Machining Efficiencies Inc., has been working in the metal cutting industry since 1972 as a field engineer and technical service department manager for metalworking fluid formulators, tool designer, quality manager, and product development manager.  Machining Efficiencies, Inc. provides manufacturers consulting and educational programs that focus on improving the efficiency of any machining process.   He’s known for effective customized training programs for manufacturing managers, process engineers and machinists who wish to identify their sub-optimized manufacturing practices. Rodak has studied and documented tool wear and machining problems for 30 years. He has a BSME from the New Jersey Institute of Technology, is a Certified Manufacturing Engineer through SME, and a Certified Metalworking Fluid Specialist through STLE (Society of Tribologists and Lubrication Engineers).

Extraneous Oils, Contamination Effects and Control Practices

Overview: These extraneous oils are commonly referred to as tramp oils. They have an extremely detrimental effect all types of metalworking fluids. There are adverse chemical reactions with the additive packages in some type of tramp oils. Biological growth is increased since some types of tramp oils contain biological nutrients. Removing these oils becomes very difficult since the oils are mutually soluble with components of the metalworking fluids. This module will discuss tramp oil effects and removal practices.

Instructor: John M. Burke, Houghton International

Biography: See above.

Microbial Concerns and Controls

Overview: MWF microbes contribute to both fluid performance and employee health problems.  In both cases, there is substantial overlap in the data pointing towards biological and non-biological causes.  IN this module we’ll discuss how to recognize when microbes are either the primary cause or a significant contributing cause of a problem. We’ll also address the primary industrial hygiene and fluid management strategies that will minimize the risk of microbial contamination problems.

Instructor: Fred Passman, BCA, Inc.

Biography: See above.

Foam Issues and Controls

Overview: Foam in a metal removal fluid and neat oil type products are influenced in many ways; chemistry of the product, the process it is used in, the configuration of the delivery/return system, contaminants that entry the system or fluid, water type,  the tooling type that is used in the process, etc.  This module will be exploring all of these areas and more based on recognizing, minimizing, and identifying the failure routes and what can be done in an anticipative manner to reduce issues to do with unwanted foam.

Instructor: John Steigerwald, Etna Products

Biography: John Steigerwald is President of ETNA-BECHEM Lubricants, Ltd and Managing Director of ETNA-BECHEM EUROPE, GMBH.  He has been in the specialty metalworking lubricants & technology industry for more than 34 years; spending the first 20 with Cincinnati Milacron Products Division in Cincinnati, Ohio.  John held various management positions from the technical, marketing, business development, sales and divisional and operation management over those 20 years. John joined ETNA Products, Inc. in 1996, leaving a large corporate environment to work in a more entrepreneurial driven environment and enterprise.  Over the 34 plus years, John has been very active in many technical and business groups in the industry, including STLE, the Precision Metal Forming Association (PMA), Society of Manufacturing Engineering (SME), and the Independent Lubricant Manufacturers Association (ILMA). He has been very active with each group, and has presented at the international, national and local levels. He has also testified on behalf of the lubricants industry multiple times in Senate Committee meetings in Washington, D.C. With STLE, John is serving on the Steering Committee on lubrication certification and certificate education programs. John is also a Past President and Executive Board Member of ILMA, representing lubricant manufacturers in the U.S., Canada and Mexico. He is the Past Liaison to the European Industry Trade Groups UEIL and UKLA on behalf of ILMA. He has also served as a member on ILMA’s Ethics Committee for the past ten years.

Corrosion: Cause, Concerns and Controls

Overview: Corrosion can be a major issue as it affects the parts produced, but it also can have some major affect on the equipment and automation in the process leading to some very costly operating cost situations.  Metal removal fluids and neat oil type products should generally be built at a minimum with in process corrosion control properties.  This module will be focused on the mechanisms to do with corrosion and what the user can do in an anticipative and predictive manner to avoid such costly situations from a part and process standpoint; type of product, what type of corrosion, what is the corrosion protection needed, chemistry of different type of metal removal products, contamination vehicles, metal types, etc.

Instructor: John Steigerwald, Etna Products

Biography: See above.

Compatibility Concerns

Overview: Metalworking fluids come in contact with many materials that are part of the work environment. These include machine tools and filters, part storage and transfer equipment and air handling devices. The components of this equipment (metals, plastics, elastomers, paint, etc) can be made of many different materials that may or may not be compatible with the components of the metalworking fluid. In this module we will review these compatibilities as well as solutions and prevention of problems.

Instructor: Greg Foltz, Cimcool Fluid Technologies, Inc.

Biography: Greg Foltz is the Engineering and Development Manager for CIMCOOL Industrial Products LLC in Cincinnati, Ohio. He received a BA in Chemistry from Thomas More College and an MBA in Management from Xavier University. He has been involved with metalworking fluids since 1978, and is responsible for the development of CIMCOOL metalworking products. Greg is a past president of ILMA (Independent Lubricant Manufacturers Association), an active member of STLE (Society of Tribologists and Lubrication Engineers) and a CMFS (Certified Metalworking Fluid Specialist). He is currently the Chairman of STLE’s Metalworking Education and Training  Committee. He has published many papers and given many presentations relating to metalworking fluids.

Metal Removal Fluid Root Cause Analysis

Overview: Most commonly, observable problems or effects are the result of the convergence of two-or more causes.  In recent years, the concept of root cause has often been misunderstood to mean a single, identifiable factor that is responsible for the undesired effect.  More correctly, root cause should suggest an image of the complex root system that sustains a tree.  Root Cause Analysis – RCA – is a powerful set of tools for helping fluid managers to better understand how multiple factors interact to cause and end result.  During this module, we’ll look at how asking the wrong diagnostic question can prevent you from solving an operational problem.  We’ll then look at two tools for doing RCA: fishbone diagramming and cause and effect diagramming.  We’ll examine how the cause and effect diagram can focus troubleshooting efforts and improve overall understanding of MWF system operations.

Instructor: Fred Passman, BCA, Inc.

Biography: See above.


Course Agenda

8:00 AM Course Introduction
8:15 AM Metal Worked and Particle Size Considerations
8:45 AM Filtration, Gravity, Vacuum or Pressure
9:45 AM Break
10:00 AM Water Quality Issues and Control Practices
10:45 AM Extraneous Oils, Contamination Effects, and Control Practices
11:30 AM Lunch
12:30 AM Microbial Concerns and Controls
1:30 PM Foam Issues and Controls
2:15 PM Break
2:30 PM Corrosion: Cause, Concerns and Controls
3:00 PM Compatibility Concerns
3:45 PM Metal Removal Fluid Root Cause Analysis
4:30 PM Course Ends
 

 

 
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