Analyze The Performance Between Pure Oil-Based Coolant And Combination Of Oil-Based Coolant With Palm Oil On Cutting Surface In Milling Operation.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ANALYZE THE PERFORMANCE BETWEEN PURE

BASED COOLANT AND COMBINATION OF

OIL-BASED COOLANT WITH PALM OIL ON CUTTING

SURFACE IN MILLING OPERATION

Thesis submitted in accordance with the requirements of the University Technical Malaysia Melaka for the Bachelor Degree of Manufacturing

Engineering in Manufacturing Process

By

Mohd Hafis Bin Bajuri

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APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial fulfilment of the requirements for the degree of Bachelor of Manufacturing (Manufacturing Process). The members of the supervisory committee are as follow:

……… Supervisor

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DECLARATION

I hereby, declare this thesis entitled “Analyze The Performance Between Pure Oil-Based Coolant And Combination Of Oil-Oil-Based Coolant With Palm Oil On Cutting Surface In Milling Operation” is the result of my own research except as cited in the

references.

Signature : ………. Author’s Name : MOHD HAFIS BIN BAJURI

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UTeM Library (Pind.1/2007)

BORANG PENGESAHAN STATUS TESIS* UNIVERSITI TEKNIKAL MALAYSIA MELAKA

JUDUL:

SESI PENGAJIAN: 2007/ 2008

Saya _____________________________________________________________________ mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di

Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.

3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.

4. **Sila t andakan (√)

Analyze The Performance Between Pure Oil Based Coolant And Combination Of Oil Based Coolant With Palm Oil On Cutting Surface In Milling Operation.

MOHD HAFIS BIN BAJURI

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA Karung Berkunci 1200, Ayer Keroh, 75450 Melaka

Tel : 06-233 2421, Faks : 06 233 2414

Perpust akawan Kolej Universit i Teknikal Kebangsaan Malaysia KUTKM, Ayer Keroh

MELAKA.

Saudara,

PENGKELASAN TESIS SEBAGAI SULIT/ TERHAD

- TESIS SARJANA MUDA KEJURUTERAAN PEMBUATAN (PROSES PEMBUATAN): TAJUK:

Sukacit a dimaklumkan bahawa t esis yang t ersebut di at as bert aj uk “ Anal yze The Perf ormance Bet ween Pure Oil Based Coolant And Combinat ion Of Oil Based Cool ant Wit h Palm Oil On Cut t ing Surf ace In Milling Operat ion” mohon dikelaskan sebagai t erhad unt uk t empoh lima (5) t ahun dari t arikh surat ini memandangkan ia mempunyai nilai dan pot ensi unt uk dikomersialkan di masa hadapan.

Sekian dimaklumkan. Terima kasih.

“ BERKHIDMAT UNTUK NEGARA KERANA ALLAH”

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ABSTRACT

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ABSTRAK

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ACKNOWLEDGEMENTS

Bismillahhirrahmanirrahim. Assalamualaikum

First of all, thank to ALLAH S.W.T for giving me the strength to complete this Project Sarjana Muda. Thank to my family for their support in every aspect.

Special thank to my supervisor, En. Ammar bin Abd. Rahman, and UTeM’s lecturer that helped and guided me throughout this project.

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LIST OF FIGURE

Figure Description Page

2.1 Cooling curves of all fluids experiment 7

2.2 A flood method of cutting fluid is applied on the workpiece. 13 2.3 A jet method of cutting fluid is applied on the workpiece directed

at the cutting zone.

13

2.4 The mist application of cutting fluid is directed at the cutting zone.

14

2.5 Milling operation consist slab, face, and end milling 19

2.6 Up milling 19

2.7 Roughness, Waviness, lay, and flaw. 23

2.8 Average Roughness (Ra). 25

3.1 Flow Chart for project 27

3.2 Conventional milling machine 31

3.3 FUCHS bacteriostatic emulsifiable coolant 32

3.4 Dimension of the workpiece 33

3.5 Carbon steel AISI 1045 workpiece 34

3.6 HSS cutting tool and tool holder 35

3.7 Portable Surface Roughness Tester: Model Surftest SJ – 301 36

3.8 Metallurgy Microscope 38

3.9 Flow chart for experiment procedure 39

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4.6 Surface Texture Image of Workpiece for Cutting Speed 400 rpm 49

5.1 Surface Roughness versus Machining Time for Cutting Speed 100 rpm

52

53

54

5.5 Surface Roughness versus Cutting Speed for 5 minutes machining

55

5.6 Surface Roughness versus Cutting Speed for 7.5 minutes machining

55

5.7 Surface Roughness versus Cutting Speed for 10 minutes machining

56

5.8 Surface Roughness versus Cutting Speed for 12.5 minutes machining

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LIST OF TABLE

Table Description Page

2.1 General Characteristics of Cutting Fluid 9

2.2 Suitable type of cutting fluids depends to materials machining operation

11

2.3 Benefits of cutting fluid 14

2.4 Composition of Carbon steel AISI 1045 21

3.1 Gantt Chart Of The Study for Projek Sarjana Muda 1 (PSM 1) 28 3.2 Gantt Chart Of The Study for Projek Sarjana Muda 2 (PSM 2) 29

3.3 Milling Machine Specification 30

3.4 Cutting tool description 34

3.5 Parameters Setting 35

3.6 General specification of Mitutoyo Surface Roughness Tester 36

3.7 Experiment design 41

4.1 Surface Roughness Result for (FUCHS) Bacteriostatic Emulsifiable Coolant Mixed With Palm Oil

44

4.2 Surface Roughness Value, Ra for Variable Machining Time 45 4.3 Surface Roughness Value, Ra for Variable Cutting Speed 46

5.1 Surface Roughness Value for (FUCHS) bacteriostatic emulsifiable coolant mixed with palm oil and (FUCHS) bacteriostatic emulsifiable coolant only

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LIST OF ABBREVIATIONS, SIGNS, AND SYMBOLS

AISI - American Iron and Steel Institute BUE - built up edge

C - Carbon

Cu - Cooper

FKP - Fakulti Kejuruteraan Pembuatan HSS - high speed steel

in - inch

mm - millimetre (metric unit)

Mn - Manganese

P - Phosphorus PSM - Projek Sarjana Muda

Ra - arithmetic mean value (roughness average) Rpm - revolution per minute

Rq - root mean square average S - Sulfur

Si - Silicon

SEM - scanning electron microscopy

UTeM - Universiti Teknikal Malaysia Melaka USA - United State of America

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CHAPTER 1

INTRODUCTION

1.1 Introduction

Cutting fluids that is also called as coolant or lubricant are widely utilized to

optimize the process of machining operations such as turning, milling, boring,

grinding, and drilling. Historically, cutting fluids have been used extensively for the

last 200 years. Today, it is estimated that over 100 million gallons of metalworking

oil are used each year in the United States, and the volume of cutting fluids used is

many times that of metalworking oil (Dilek Senay, 2001).

Nowadays, cutting fluids are very important in machining processes. It is used

extensively in machining as well as abrasive machining processes. It is used to

reduce the detrimental effects of heat and friction on both tool and workpiece (Lopez

de Lacalle, 2004). Cutting fluids are also used to carry away the heat in machining

operations. This excessive heat can bring damage to the microstructure of metals.

The metal removal rates can be increase by proper use of coolants. Another benefit

of cutting fluid is to improve part quality and dimensional accuracy.

According to Kalpakjian (2001), the effectiveness in cutting operation depends on

several numbers of factors such as the method used to apply the cutting fluid,

temperature encountered, cutting speed and type of machining process. In machining,

the energy that expended in cutting is transformed into heat. The deformation of the

metal to create chips and the friction of the chip sliding across the cutting tool

produce heat. The primary function of cutting fluids is to cool the tool, work piece,

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adhesion on the contact edges that causes a built-up edge on the cutting tool or insert.

Cutting fluids also help prevent rust and corrosion and flush chips away.

There is a wide variety of cutting fluids available today. Many new coolants have

been developed to meet the needs of new materials, new cutting tools, and new

coatings on cutting tools. The most common cutting fluids used today belong to one

of two categories are oil-based fluids including straight oils and soluble oils and

chemical fluids including synthetics and semi synthetics. Proper selection and use of

cutting fluids can help to get good result in surface machining.

However, the usage of cutting fluid can also cause problem in a few cases. The direct

contact of machines operator with cutting fluids may cause skin respiratory diseases.

So now, new development is done to produce the friendly environmental cutting

fluid. This type of cutting fluid use the vegetable oil based as compound in cutting

fluid. It avoids the already problem those come from conventional cutting fluid.

Now, the development of palm oil to be a cutting fluid is done. However, it just

reached to the early stages. There are still more improvement must be done to

achieve it.

This research is conducted to analyze the performance between pure oil based

coolant and combination of oil-based coolant with palm oil on cutting surface in

milling operation. The evaluations are defined from the experiment outcomes. All the

findings from this study will prove that whether palm oil is suitable for use as cutting

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1.2 Problems Statements

The problems that be based on this study are:

i. There are limited studies or information that exists regarding to the issue of

the palm oil as the cutting fluid in milling operation.

ii. The current coolants are harmful to the operator compared to the new formula

coolant based on vegetable oil (organic) like palm oil which is environmental

friendly.

iii. There have no study proving that whether palm oil is a suitable solution to

mix with coolant. What happened if both of them are mixed?

1.3 Objectives of Project

In recognition the importance of coolant in machining, this project is tried to achieve

the following objectives:

i. To study the performance between pure oil based coolant and combination of

oil based coolant with palm oil on cutting surface in milling operation.

ii. To analyze the surface roughness and observe the surface texture of the

surface machining that was produced on the workpiece from the usage of the

oil-based coolant mix with palm oil and relating them with the parameters

involves.

iii. To compare and identify the best coolant between the oil-based coolant and

the combination of oil-based coolant with palm oil in the aspect of surface

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1.4 Scope of Project

This project is done to analyse the coolant application in milling operation in

Manufacturing Laboratory of UTeM. The coolant to be used in this project is a

bacteriostatic emulsifiable cutting oil. The bacteriostatic emulsifiable cutting oil has

mixed with pure palm oil. This coolant afterwards is applied in face milling

operation. All machining processes performed on carbon steel AISI 1045 with

several parameters which are time of machining and cutting speed. This study will be

focusing on the surface of machining consist of the surface roughness and surface

texture. All of the samples will be analyzed using surface roughness tester and

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CHAPTER 2

LITERATURE REVIEW

2.1 Cutting Fluid

Cutting fluids play a critical role on metallic surfaces in cutting and forming

operations. During the machining processes of a metal, a considerable quantity of

heat is generated. It happens mainly due to the high plastic deformation in the

primary shear zone and also to the friction of the chip on the surface. The condition

of friction and temperature will cause tool wear. It also results in a poor surface

finish and incorrect dimension. Cutting fluids are used to reduce the detrimental

effects of heat and friction on both tool and workpiece. The cutting fluid produces

three positive effects in the process whish are heat elimination, lubrication on the

chip and tool interface, and chip removal (López de Lacalle et al., 2006). A cutting

fluid's effectiveness depends on factors such as the method used to apply the cutting

fluid, temperatures encountered, cutting speed, and type of machining process

(Kalpakjian, 1991). A fluid's cooling and lubrication properties are critical in

decreasing tool wear and extending tool life. Cooling and lubrication are also

important in achieving the desired size, finish and shape of the workpiece.

2.1.1 Principle of Cooling and Lubrication

Cooling give influences to machining in various ways. At the contact between the

chip and tool, cooling can reduce the chip temperature. It also affects directly the

friction force between the chip and tool. However, contact pressures are so high that

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Cooling is mainly indirect via modified conduction through the chip. For the cutting

edge, the coolant always plays a major role in maintaining the machined material at

ambient temperature.

As coolers, cutting fluids decrease cutting temperature through the heat dissipation

(cooling). When water based fluids are used, cooling is more important than

lubrication. It was experimentally proved (Shaw, et al., 1951) that the cutting fluid

efficiency in reducing temperature decreases with the increase of cutting speed and

depth of cut.

As lubricant, the cutting fluid works to reduce the contact area between chip and tool

and its efficiency depends on the ability of penetrating in the chip-tool interface and

to create a thin layer in the short available time. This layer is created by either

chemical reaction or physical adsorption and must have a shearing resistance lower

than the resistance of the material in the interface. In this way it will also act

indirectly as a coolant because it reduces heat generation and therefore cutting

temperature (Sales et al., 2001).

2.1.2 Cooling Ability of Cutting Fluids

Aiming to classify the main cutting fluids based on their cooling ability, Sales (1999)

developed a methodology which consisted in heating a standard workpiece and

monitoring the cooling curve of it. This workpiece was fixed to the clutch of jigs and

rotated at 150 rpm and its temperature was measured using an infrared sensor. The

data acquisition started when the workpiece temperature reached 300°C and the

measurement continued up to room temperature. Emulsions and synthetic fluids were

applied using a concentration of 5%. Synthetic fluids are containing water and

additives. The synthetic oil 1 is different from synthetic oil 2 due to small variations

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Figure 2.1: Cooling curves of all fluids experiment (Sales, 1999).

The cooling ability in crescent order is dry cutting, neat, oil emulsion, synthetic-2,

water and synthetic-1. The fact that synthetic oil 1 presented a cooling ability greater

than water, which theoretically has greater convection ability, was a surprise. A

deeper analysis of the curves behavior in high temperature showed that water

presented lower cooling ability even than synthetic oil 2 and neat oil (Sales et al.,

2001).

The explanation of these results may be found on the phenomenon occurring when a

fluid like water, with low ebullition point (100°C), starts contacting a body in high

temperatures. At this moment the quick heat transfer causes the liquid evaporation.

This process reduces a little the hot body temperature, but the vapor forms a barrier

preventing fresh volume of liquid, from reaching its surface and, therefore, decreases

the heat transfer efficiency. Another important factor is the fluid wet ability, which is

regularly higher for cutting fluids than for water. The higher wet ability of the cutting

fluid implies in less splashing action and therefore a greater chance for heat exchange

(Sales et al., 2001).

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2.1.3 Types of Cutting Fluids

The main types of cutting fluids fall into two categories based on their oil content:

• Oil-Based Fluids - including straight oils and soluble oils

• Chemical Fluids - including synthetics and semi-synthetics

2.1.3.1 Straight Oil

Straight oils are non-emulsifiable and are used in machining operations in an

undiluted form. They are composed of a base mineral or petroleum oil and often

contain polar lubricants such as fats, vegetable oils and esters as well as extreme

pressure additives such as Chlorine, Sulphur and Phosphorus. Straight oils provide

the best lubrication and the poorest cooling characteristics among cutting fluids

(Boothroyd and Knight, 2006).

2.1.3.2 Soluble Oil

Soluble Oil Fluids form an emulsion when mixed with water. The concentrate

consists of a base mineral oil and emulsifiers to help produce a stable emulsion. They

are used in a diluted form (usual concentration = 3 to 15%) and provide good

lubrication and heat transfer performance. They are widely used in industry and are

the least expensive among all cutting fluids (Boothroyd and Knight, 2006).

2.1.3.3 Synthetic Fluid

Synthetic Fluids contain no petroleum or mineral oil base and instead are formulated

from alkaline inorganic and organic compounds along with additives for corrosion

inhibition. They are generally used in a diluted form (usual concentration = 3 to

10%). Synthetic fluids often provide the best cooling performance among all cutting

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2.1.3.4 Semi-synthetic Fluid

Semi-synthetic fluids are essentially combination of synthetic and soluble oil fluids

and have characteristics common to both types. The cost and heat transfer

performance of semi-synthetic fluids lay between those of synthetic and soluble oil

fluids (Boothroyd and Knight, 2006).

Table 2.1: General Characteristics of Cutting Fluid (Nachtman and Kalpakjian, 1985).

Function Straight oils Soluble Oil Synthetic Fluids

Analyze The Performance Between Pure Oil-Based Coolant And Combination Of Oil-Based Coolant With Palm Oil On Cutting Surface In Milling Operation.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA