What is cutting oil emulsification and how does it impact machining operations?

Cutting oil emulsification is the process of mixing oil with water to form a stable emulsion used in water-soluble cutting fluids. Proper emulsification ensures consistent lubrication and cooling during machining. However, instability in the emulsion, caused by factors like hard water minerals, contamination, or incorrect mixing ratios, can lead to separation of oil and water. This separation reduces the effectiveness of the cutting fluid, leading to inadequate lubrication, increased tool wear, and poor surface finishes. Maintaining proper emulsification through correct mixing procedures and using suitable emulsifiers is vital for optimal machining performance.