The economic evaluation of metalworking fluids is undergoing a fundamental shift. While many companies still focus on the price per kilogram of metalworking fluids, rising tooling costs are significantly shifting priorities. The real lever for cost optimization no longer lies primarily in the purchase price of consumables, but in their impact on process efficiency.
Tool Costs Under Structural Pressure
Prices for cutting tools – particularly carbide tools – have not only been volatile in recent years but have also trended structurally upward. For the tool industry, this means persistently rising costs that are passed on to machining companies. Higher tool prices, increasing raw material surcharges, and tool changes place a direct burden on production. At the same time, this increases the importance of all factors that extend tool life and reduce tool changes. Coolant, which was previously viewed as a mere consumable, is increasingly becoming a strategic variable in the machining process.
From Cost Factor to Performance Lever
In practice, coolant is often viewed in isolation and evaluated based on its purchase price. However, this perspective usually falls short. What matters is not necessarily how much a coolant costs, but rather the contribution it can make toward reducing the cost per component.
A well-tuned coolant can make a difference precisely here. Through targeted optimization of its cooling and lubricating properties, it influences key wear mechanisms and helps to increase process stability and performance. The effect is not necessarily reflected in the price per kilogram, but rather in extended tool life, reduced downtime, and greater process reliability.
The effect of a metalworking fluid unfolds in interaction with the tool, the material, and the process parameters. Efficient heat dissipation can reduce the temperature at the tool cutting edge and slow down temperature-driven wear mechanisms. Stable lubricant film formation reduces friction and mechanical stress, which has a positive effect on wear. Especially in demanding applications, reliable chip removal is also crucial for preventing tool damage and surface defects.
What Practice Shows
It is therefore often worthwhile to look beyond the tool itself and consider the overall coolant strategy. Anyone seeking to improve the cost-effectiveness of their machining processes must take the entire machining process into account.
In a customer trial, it was demonstrated for the system in question that switching from the current emulsion–with a concentration of up to 9.0%–to a Petrofer product at a concentration of 6.0 to 7.5% not only reduced consumption but, above all, significantly improved process stability. In this process configuration, the Petrofer product ran for over eight months without replacement, even during extended machine downtime. Tool life was more than doubled. At the same time, the critical tool life was extended from 50 to 60 minutes of cutting time. A complete success that can be measured in terms of cost per component.
Conclusion and Outlook
For machining companies, current market trends require a shift in thinking. Rising tool costs are increasing pressure on purchasing and production, while the value of process-supporting measures is growing. The advantage of the coolant lies in its comparatively quick and cost-effective adaptability, which shifts its role from that of a mere consumable to an economically significant lever that contributes to reducing overall manufacturing costs. This makes it a key component within a holistic optimization strategy.
