Emulsol TUV-95

Emulsol TUV-95 – a water-soluble cutting fluid for metalworking

TUV-95 Emulsol is a classic oil-containing water-miscible metalworking fluid for mechanical metalworking operations. The product is supplied as a concentrate and, after proper mixing with water, forms a working emulsion used for cooling the cutting zone, reducing friction, protecting equipment against corrosion, and stabilizing the machining process.
TUV-95 belongs to the category of traditional emulsols that retain practical value where enhanced lubricating properties, good machining cleanliness, good surface finish, and predictable operation on general-purpose equipment are required. It is not a synthetic or semi-synthetic metalworking fluid, so its main strength is lubrication, not maximum system cleanliness or minimum dependence on water quality.
TUV-95 is most appropriate for standard production tasks where a plant needs a proven oil-containing emulsol with reasonable operating economics, effective performance on steels, cast iron, and a range of hard metals, and predictable behavior in use.

Purpose

TUV-95 Emulsol is used for:

• cooling the tool and the workpiece in the cutting zone;
• reducing friction between the tool and the metal;
• reducing cutting-tool wear;
• improving the quality of the machined surface;
• facilitating chip removal;
• protecting equipment and parts against corrosion;
• stabilizing the cutting process.

Where it is used

TUV-95 is used:

• in machine building;
• in metalworking shops;
• in repair production;
• in serial and small-batch production;
• on general-purpose turning, milling, and drilling machines;
• on some CNC machines operating at low and medium cutting speeds;
• in centralized metalworking-fluid supply systems, provided that the system is properly maintained.

Main properties

Main properties of TUV-95:

1. classic oil-containing water-miscible metalworking fluid;
2. enhanced lubricating properties;
3. good machining cleanliness;
4. ability to achieve good surface finish when the concentration is selected correctly;
5. stable emulsion when prepared correctly;
6. corrosion protection for equipment and parts;
7. predictable performance under serial-production conditions;
8. low working-solution cost.

The strength of TUV-95 lies in the combination of lubricating properties, machining cleanliness, surface quality, and economical use of the working emulsion.

Materials for which it is used

The coolant is used for machining:

• structural steels;
• carbon steels;
• alloy steels;
• cast iron;
• stainless steels;
• aluminium alloys and certain non-ferrous metals, following production trials.

For steels and cast iron, this is a more typical field of application. For aluminum alloys and some non-ferrous metals, practical verification under actual production conditions is advisable.

For which machining conditions is Emulsol TUV-95 intended?

TUV-95 coolant is most effective at low and medium cutting speeds, when lubrication properties and tool protection are important.

Under such conditions, a classic oil-containing emulsion often performs better than some synthetic products when the main requirement is not maximum system cleanliness, but practical lubrication and a predictable result in standard machining.

For high-speed machining (HSM), modern machining centres and operations involving high heat generation, it is recommended to use semi-synthetic or synthetic coolants. For example, the semi-synthetic coolant Defender Pro or the synthetic coolant Defender Ultra.

Recommended concentrations of the working emulsion

The recommended values may need to be adjusted depending on the material, cutting parameters and production conditions.

Important note on water

As an oil-containing emulsol, TUV-95 is more sensitive to water quality than synthetic metalworking fluids. This is one of the key characteristics of the product.
For hard or problematic water, the following may be required:

• preliminary treatment;
• softening;
• mineralization control;
• adjustment of the emulsion-preparation procedure according to the actual water quality.

Unsuitable water may lead to emulsion instability, separation, deterioration of corrosion protection, and reduced service life of the working solution.

Operating features

For stable operation of TUV-95, it is necessary to:

• use metalworking-fluid systems with proper removal of chips, sludge, and abrasive particles;
• regularly remove mechanical contamination from tanks and circulation systems;
• control the concentration of the working emulsion;
• correct the concentration in time;
• maintain system cleanliness, especially in warm periods;
• avoid prolonged operation in a contaminated system
• store the concentrate in tightly closed containers at temperatures not below +5 °C.

Accumulated contamination accelerates biological activity, worsens emulsion condition, and shortens service life.

Important note before preparing the emulsion

Before preparing the working emulsion, the TUV-95 concentrate must be thoroughly mixed until homogeneous.
Simply rolling a 200-liter drum on its side does not ensure proper mixing of the concentrate. In that situation, the drum itself often rotates, while the liquid inside, due to inertia, mixes insufficiently.
For practical mixing under production conditions, a clean metal pipe or another suitable clean rod may be inserted through the drum opening. The concentrate should then be mixed with several circular movements in one direction and then in the opposite direction. This is far more effective than simply rolling the drum.

How to prepare the emulsion correctly

To obtain a stable working emulsion, it is necessary to:

1. Thoroughly mix the concentrate until homogeneous before preparation.
2. Not treat simple rolling of the drum as a sufficient mixing method.
3. If necessary, mix the concentrate through the drum opening with a clean metal pipe or another suitable clean tool.
4. Use prepared water or water suitable in quality.
5. Follow the recommended concentration.
6. Check concentration with a refractometer during operation.

IMPORTANT: when diluting, the concentrate must be poured into water. Water must not be poured into the concentrate.

Economics of use

One of the practical advantages of TUV-95 is the low cost of the working solution. With the correct concentration and normal system maintenance, the product allows a working emulsion with a clear and predictable cost structure, which is important for serial and small-batch production.
This is one of the reasons why TUV-95 remains attractive for enterprises that need not just a newer-sounding product, but a working emulsion with predictable operating cost

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Advantages

1. enhanced lubricating properties;
2. good machining cleanliness;
3. good surface finish when used correctly;
4. effective performance on steels, cast iron, and a range of hard metals;
5. stable emulsion when prepared correctly;
6. corrosion protection;
7. predictable behavior in operation;
8. low working-solution cost.

Conclusion

TUV-95 Emulsol is a classic oil-containing water-miscible metalworking fluid for mechanical metalworking operations, intended for standard production tasks where lubricating properties, corrosion protection, machining cleanliness, surface quality, and stable operation with proper emulsion preparation are important.
The product is most appropriate for general-purpose equipment, low and medium cutting speeds, machining of steels, cast iron, and a range of hard metals, as well as for plants that need a proven traditional emulsol with predictable operating economics.
At the same time, TUV-95 requires closer attention to water quality, system cleanliness, concentration control, and proper concentrate mixing than synthetic metalworking fluids.

FAQ

What is TUV-95 Emulsol?

It is a classic oil-containing water-miscible metalworking fluid for mechanical metalworking operations.

What is TUV-95 used for?

It is used for turning, milling, drilling, thread cutting, boring, honing, and other standard metalworking operations.

How should the emulsion be prepared correctly?

The concentrate is added to water while mixing until the required working-emulsion concentration is obtained. Before that, the concentrate must be thoroughly mixed. Water must not be poured into the concentrate.

Is it enough to simply roll the drum to mix the concentrate?

No. Simply rolling the drum on its side does not ensure proper mixing. For a 200-liter drum, it is better to mix the concentrate through the opening with a clean metal pipe or another suitable clean tool.

Is TUV-95 suitable for stainless steel?

Yes, but more difficult operations require increased concentrations and proper control of emulsion condition.

Does water quality matter for TUV-95?

Yes. For an oil-containing emulsol, water quality is very important and directly affects emulsion stability.

What is the service life of the working emulsion?

With concentration control, system cleanliness, and proper maintenance, the emulsion can operate for a long time without complete replacement.