Lubricant-coolant Biol / Cutting fluid Biol

Biol cutting fluid

What BIOL is

BIOL is a concentrated water-miscible metalworking fluid used to prepare a working solution that is delivered to the cutting zone between the tool and the workpiece.
When correctly prepared and maintained, the working solution performs several main functions:

• removes heat from the cutting zone;
• reduces friction between the tool and the workpiece;
• helps remove chips and machining residues;
• supports corrosion protection of metal surfaces.

The performance of a metalworking fluid depends not only on the concentrate itself, but also on the working concentration, water quality, machining conditions, equipment condition and proper system maintenance.

Key characteristics

Long-term industrial use and successive formulation updates have kept BIOL relevant for serial production, maintenance workshops, machine-building plants and metalworking operations.
BIOL can be considered for:

• serial metal machining;
• repair and machine shops;
• machine-building plants;
• production of metal parts and components;
• local metalworking-fluid circulation systems;
• centralized systems where the operating conditions and equipment are suitable.

More demanding materials, severe cutting conditions or special technical requirements may call for a more specialized metalworking fluid.

Machining operations

BIOL is primarily intended for standard machining operations, including:

• turning;
• milling;
• drilling;
• boring;
• threading;
• grinding.

For severe cutting conditions, deep-hole drilling, broaching and other operations with high tool loads, the suitability of BIOL should be checked against the requirements of the specific process.

Workpiece materials

The main application range of BIOL includes:

• carbon and structural steels;
• low-alloy and alloy steels;
• stainless steels;
• cast iron.

For aluminium and its alloys, copper, brass, bronze, titanium and other special materials, the product should be selected with regard to the specific machining operation and surface requirements.
For such applications, a more specialized metalworking fluid from the product range may be a better choice.

When BIOL is a practical choice

BIOL is worth considering when:

• a water-miscible metalworking fluid is required for standard machining operations;
• the plant works mainly with steels and cast iron;
• a balance between working performance and product cost is important;
• there are no special requirements for particularly severe cutting conditions;
• there are no elevated environmental requirements for the formulation;
• the system allows the working concentration and solution condition to be monitored correctly.

Typical working concentration: 5%

The typical BIOL concentration for initial system filling is 5%.
The concentrate is mixed with water in the quantity required to prepare a 5% working solution.
The concentration should not be reduced arbitrarily simply to lower consumption.
An excessively low concentration may reduce:

• lubricating performance;
• corrosion protection;
• stability of the working solution.

Increasing the concentration above the required level does not automatically improve machining performance and increases concentrate consumption.
For typical operating conditions, 5% is the starting concentration.
Why a 2% solution is recommended for make-up
During operation, part of the working fluid is lost with chips and workpieces, while part of the water evaporates.
Water evaporates much faster than the components of the concentrate.
If these losses are continuously replaced with a 5% solution, the concentration of the metalworking fluid in the tank may gradually increase.
For this reason, a 2% BIOL solution is recommended for routine make-up.
A practical approach is:

• initial system filling — 5%;
• monitor the condition and concentration of the working solution during operation;
• use a 2% solution for routine make-up;
• if the actual concentration deviates significantly, correct it based on the measured value.

This principle applies to water-miscible metalworking fluids in general: make-up should take into account both mechanical losses of working fluid and the preferential evaporation of water.

Why a 2% solution is recommended for make-up

During operation, part of the working fluid is lost with chips and workpieces, while part of the water evaporates.
Water evaporates much faster than the components of the concentrate.
If these losses are continuously replaced with a 5% solution, the concentration of the metalworking fluid in the tank may gradually increase.
For this reason, a 2% BIOL solution is recommended for routine make-up.
A practical approach is:

• initial system filling — 5%;
• monitor the condition and concentration of the working solution during operation;
• use a 2% solution for routine make-up;
• if the actual concentration deviates significantly, correct it based on the measured value.

This principle applies to water-miscible metalworking fluids in general: make-up should take into account both mechanical losses of working fluid and the preferential evaporation of water.

Water quality

Water makes up most of the working solution, so its properties have a direct effect on metalworking-fluid performance.
Excessive hardness, high salt content or other deviations may contribute to:

• deposit formation;
• foaming;
• changes in working-solution stability;
• corrosion-related problems;
• shorter periods of stable fluid operation.

The public product page should not make the absolute claim that BIOL performs identically with water of any hardness.
Before preparing a large volume of working solution, it is advisable to know the main characteristics of the process water used at the facility.
See also the Novohim Reference Centre article on water preparation for metalworking fluids.

Monitoring during operation

The condition of the working solution should be checked periodically.
Particular attention should be paid to:

• concentration;
• unusual odour;
• foaming;
• contamination by chips and sludge;
• tramp-oil contamination;
• deposits in the tank;
• signs of corrosion on parts or equipment.

Concentration can be monitored with a refractometer using the procedure specified for the particular product.

Main limitations

BIOL should not automatically be used:

• for every metal without checking suitability;
• for particularly severe cutting conditions;
• for deep-hole drilling without confirming the process requirements;
• for non-ferrous metals without checking compatibility;
• below the recommended concentration without a technical justification;
• after mixing with a product of unknown composition;
• in a contaminated system without prior cleaning.

Correct metalworking-fluid performance depends not only on selecting the concentrate but also on proper system maintenance.

Storage and safety

Store BIOL concentrate in its tightly closed original packaging in accordance with the conditions specified in the manufacturer’s documentation.
Do not allow the concentrate to become contaminated with foreign substances.
When handling the concentrate and working solution, follow industrial hygiene practices and use personal protective equipment in accordance with the product documentation.

FAQ

Is BIOL supplied ready for use or as a concentrate?

BIOL is supplied as a concentrate. A water-based working solution is prepared before use.

What is the typical BIOL concentration?

For initial system filling, the typical concentration is 5%.

What solution should be used for routine make-up?

A 2% solution is recommended for typical make-up because water evaporates faster than the components of the concentrate during operation.

Why not use a 5% solution for every make-up addition?

If the initial concentration is used for every make-up while water continues to evaporate, the metalworking-fluid concentration in the tank may gradually increase.

Can only water be added?

Adding only water without concentration control is also undesirable. Working fluid is also lost with chips, workpieces and other mechanical losses, so a weaker working solution is used for routine make-up.

Can BIOL concentration be checked with a refractometer?

Yes. The correct procedure and product-specific data should be used. The necessary technical information is supplied separately to customers.

Can BIOL be mixed with another metalworking fluid?

Not without checking compatibility.

Which materials is BIOL intended for?

Its main application range includes structural, alloy and stainless steels, as well as cast iron. Suitability for non-ferrous metals and special alloys should be checked separately.

How does BIOL differ from BIOL Universal?

BIOL is a traditional cost-effective metalworking fluid for common machining operations. BIOL Universal places greater emphasis on modern environmental requirements for the formulation.

Does the working solution have to be replaced after a fixed period?

No. Its condition depends on operating conditions, water quality, contamination, concentration and maintenance. One universal service interval for all systems would be incorrect.