Cutting fluids, also called metalworking fluids (MWFs) and coolants, cool, lubricate, and reduce friction between metal parts during machining operations. They also flush chips away from the cutting zone and help protect tools and workpieces from corrosion. Common applications include cutting, grinding, forming, honing, tapping, rolling, sawing, stamping, and other high-friction operations.
Metalworking Fluids: Essential Guide for Cooling, Lubrication & Tool Life
Understand how cutting fluids work, compare the main types, and learn maintenance and safety tips to keep your machining operations running efficiently.
Metalworking Fluids
Functions of Metalworking Fluids
✔︎ Control and dissipate heat
✔︎ Reduce friction between the tool and the workpiece
✔︎ Extend tool life and improve material removal rate
✔︎ Flush chips away from the cutting area
✔︎ Protect against rust and corrosion
✔︎ Improve surface finish and part integrity
Types of Cutting Fluids & Coolants
Different metalworking tasks require specific fluids. Determine your application’s
primary purpose first and use this guide to select the cutting fluid with the right
balance of cooling and lubrication.
Common Cutting Fluid Formulations
The formula defines the chemical composition of a cutting fluid or coolant. It determines whether the lubricant can perform at high speeds, resist extreme temperatures, or handle heavy loads under pressure. Many cutting fluids are available in environmentally friendly formulas. These options help protect workers and the environment while delivering the cooling and lubricating performance your operation needs.
Aerosols: Ideal for drilling, forming, and milling nonferrous metals; reduce heat and can remain on the workpiece to minimize corrosion.
Emulsions: Oil-and-water mixtures used on ferrous and nonferrous metals.
Gels or Spray Gels: High-performance lubricants for ferrous and nonferrous metals; reduce tool wear, improve performance, and stand up to high-pressure applications.
Liquids: Reduce friction and heat when drilling, tapping, or reaming aluminum, titanium, and Inconel.
Naphthenic Oil-Based Oils: Economical mineral oils with low pour points and high solvency; provide precision finishes, extended tool life, and minimal odor.
Natural Ingredient Fluids: Biodegradable, nontoxic blends that increase lubricity and reduce friction for moderate- to heavy-duty machining.
Pastes: Easy-to-apply single-point lubricants for tapping, drilling, or reaming; require little cleanup and are commonly used with a drip tool or brush.
Semi-Synthetic Fluids (SSF): A mix of oil and water with synthetic additives; low-foaming, easy to maintain, and ideal for nonferrous metals like aluminum and titanium; can be used as an economical alternative to synthetic fluids.
Solid Sticks or Blocks: Economical options for drilling, deburring, grinding, and tapping; applied to belts or discs before start-up.
Spray Foams: High-performance cutting fluids that adhere to material surfaces for extended lubrication. Ideal for cutters, drills, end mills, and taps.
Straight Oils: Mineral or vegetable oils used when lubricity is more critical than cooling; contain no water or additives.
Synthetic Fluids (SF): Contain no oil and are composed of lubricating polymers with organic and inorganic materials dissolved in water; provide excellent cooling and the most biostable option for grinding and moderate-duty machining.
Water-Soluble Oils (WSO): Mineral or vegetable oils emulsified in water; offer strong corrosion protection and lubricity for moderate- to heavy-duty applications but may foam in high-pressure/high-volume systems.
Wax: Non-toxic lubricant applied directly to a cutting surface to reduce friction and allow smooth tool movement.
Selecting the Best Cutting Fluid for the Job
Consider these factors before you choose:
1
Material Being Machined
Different metals require different cutting fluids and additives.
2
Water Chemistry
Because diluted cutting fluids are typically 90–98% water, the chemistry of your water supply affects performance.
3
Current Coolant Performance
Evaluate the strengths and weaknesses of what you use now to identify desired improvements.
4
Fluid Type Preference
Water-soluble oils, semi-synthetics, and synthetics each have unique cooling and lubrication characteristics.
5
Budget and Preferences
Price and personal preference often influence the final choice.
Additives That Improve Performance
Safety and Maintenance for Cutting Fluids
Routine Checks & Warning Signs
Maintain your machinery by replacing fluids and components on a regular schedule. Warm weather (summer) is a good time for preventive maintenance because higher temperatures and changes in chemical exposure can stress cutting fluids. Watch for these warning signs that your metalworking fluid needs attention:
Irregular appearance (color change, cloudiness, separation)
Excessive foam
Chips, swarf, or tramp oil floating on the fluid
Strong/objectionable odor
Low sump level
Dirty machines or trenches
Worker symptoms (skin irritation or respiratory complaints)
If any of the above appear, check concentration, skim tramp oil, clean or filter the system, correct aeration, and refresh or replace the fluid per the manufacturer’s guidance.
Safe Handling
Wear OSHA-approved personal protective equipment (PPE) such as gloves, eye protection, and respiratory protection.
Prevent exposure to mist and debris to avoid skin irritation, respiratory issues, and increased risk of cancer.
Routine Maintenance
Run an industrial sump cleaner through the system every 6–12 months.
Add antimicrobial additives monthly to prevent bacterial growth and odors. Adding the antimicrobial on Friday morning will reduce the "Monday-morning smell".
Remove swarf and tramp oil daily to keep fluids clean.
Let machines run at least an hour a day to aerate the sump or use an aerating pump. Use an aerating pump if it isn't possible to run the machine daily.
Increase performance by mixing cutting fluid before adding it to the sump.
Check sump concentration weekly using a hand-held refractometer and maintain correct levels with regular make-up additions. Never add straight water or coolant concentrate to the sump, and always add coolant concentrate to water when mixing.
Tip: Tramp oil, which is the thin film oil that collects on the surface of metalworking fluids, should be skimmed off regularly with a wheel skimmer or similar device to avoid contaminating the metalworking fluid.