UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Performance Analysis of Evaluation between
Oil-Based Coolant and Combination of Oil-Oil-Based
Coolant with Palm Oil on Cutting Surface in
Turning Operation
Thesis submitted in accordance with the requirements of the Malaysia Technical
University of Malacca for the Bachelor Degree of Manufacturing Engineering in
Manufacturing Process
By
Mohd Akram Zaki Mohd Sabri
(B050410045)
UTeM Library (Pind.1/2007)
/
BORANG PENGESAHAN ST AT US T ESIS*
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 (√)
Performance Analysis of Evaluation between Oil-Based Coolant and Combination of Oil-Based Coolant with Palm Oil on Cutting Surface in Turning Operation
MOHD AKRAM ZAKI MOHD SABRI
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan) (Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Mal aysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
TIDAK TERHAD TERHAD
DECLARATION
I hereby, declared this thesis entitled “Performance Analysis Of Evaluation Between Oil-Based Coolant And Combination Of Oil-Oil-Based Coolant With Palm Oil On Cutting
Surface In Turning Operation” is the results of my own research except as cited in references.
Signature :……….
Author’s Name : MOHD AKRAM ZAKI MOHD SABRI
APPROVAL
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing
Process). The members of the supervisory committee are as follow:
ABSTRACT
ABSTRAK
DEDICATION
ACKNOWLEDGEMENTS
Alhamdulillah and Thank to Allah S.W.T. with all His Gracious and His Merciful for giving me strength and ability to accomplish this project research successfully. I would like to take the utmost opportunity to express my sincere and gratitude to my supervisor, Mr. Mohamad Nizam bin Ayof, for giving me support and guidance throughout this Final Year Project until this completing project level.
Also the greatest thanks to my beloved parents and family who always pray and give the encouragement while pursuing my research. Their sacrifices are never being forgotten.
Besides, thanks a lot to Prof. Dr. Mohd Razali Bin Muhamad, Dean of Manufacturing Engineering Faculty, Universiti Teknikal Malaysia Melaka,Dr Mohd Rizal Salleh as head of Department of Manufacturing Process, Mr Sivarao, and also Dr Vijay as well as to all lecturers of Faculty of Manufacturing Engineering.
I also would like to convey my biggest appreciation to all FKP technicians for supporting me in accomplishes my final year project without hesitation. All knowledge and experience I gained would not be forgotten.
2.4 Advantages and Disadvantages According to Types of Cutting Fluids 11
2.6 Cutting Fluids Selection and Applications 16
2.6.1 Selection of Cutting Fluids 16
2.6.2 Cutting Fluids Application Methods 19
2.6.2.1 Manual Application 19
2.6.2.2 Flood Application 19
2.6.2.3 Jet Application 20
2.6.2.4 Mist Application 21
2.7 Benefits of Cutting Fluids 22
2.8 New Development of Cutting Fluids 24
2.8.1 Introduction 24
2.8.2 Cutting Fluid from Vegetable Oil 24
2.8.3 Cutting Fluid from Soy Bean Oil 26
2.9 Palm Oil: A Source from Malaysia to Be Developed 27
2.11.5.1 Speed 33
2.11.5.2 Feed 34
2.11.5.3 Depth of Cut 34
2.11 Surface Metrology 35
2.11.1 Introduction to Surface Metrology 35
2.11.2 Surface Evaluation 35
2.11.3 Surface Texture 35
2.11.4 Surface Roughness 37
2.11.5 Importance of Surface Characterization 39 3.0 METHODOLOGY
3.1 Introduction 40
3.1.1 Planning 41
3.2 Methodology Flowchart 42
3.3 Selection of Machine / Equipment 43
3.3.1 Conventional Lathe Machine 43
3.3.2 Band Saw 44
3.3.3 Surface Roughness Tester 45
3.3.4 Metallurgy Microscope 46
3.4 Selection of Cutting Fluids 47
3.4.1 Bacteriostatic Emulsifiable Oil (Fuchs) 47
3.9 Experiment Procedure 52
3.9.1 Experiment Flowchart 52
3.9.2 Preparation of Workpiece 54
3.9.3 Preparation of Cutting Fluid 55
3.9.4 Preparation of Cutting Tool 56
3.9.5 Machining Parameters 57
3.9.6 Machining Operation and Procedure 59
3.9.7 Surface Roughness Operating Procedure 60 3.9.8 Metallurgy Microscope Operating Procedure 61
4.0 RESULTS
4.1 Introduction 62
4.2 Surface Roughness Result for Bacteriostatic Emulsifiable Cutting Fluids
mixed with Palm Oil 63
4.2.1 Surface Roughness Analysis for Bacteriostatic Emulsifiable Cutting
Fluids mixed with Palm Oil 65
4.3 Surface Roughness Result for Bacteriostatic Emulsifiable Cutting Fluids used
as Comparison Result 68
4.4 Surface Texture Observation 72
4.5 Surface Roughness Comparison between Bacteriostatic Emulsifiable and Bacteriostatic Emulsifiable Cutting Fluids mixed with Palm Oil 77
4.5.1 Comparison of Surface Roughness in the Aspect of Cutting
Speed 77
4.5.2 Comparison of Surface Roughness in the Aspect of Machining Time
81
5.0 DISCUSSION 85
6.0 CONCLUSION & RECOMMENDATIONS 87
REFERENCE 89
APPENDICES
APPENDIX A
Gantt chart For PSM 1 Gantt chart For PSM 2 APPENDIX B
Table of Surface Roughness Result APPENDIX C
LIST OF FIGURES
2.1 A flood method of cutting fluid is applied on the workpiece 20
2.2 A jet method of cutting fluid is applied on the workpiece directed at
the cutting zone 20
2.3 The mist application of cutting fluid is directed at the cutting zone 21
2.4 Lathe machine and parts of lathe machine 29
2.5 Turning operation 33
2.6 Standard terminology and symbol to describe surface finish.
The quantities are given in µin 36
2.7 The Arithmetic mean value, Ra 38
2.8 Coordinate used for surface roughness measurement 38
3.15 Cutting tool terminology 56
3.16 Pre machining operation 59
4.1 Graph for surface roughness Vs machining time for Bacteriostatic Emulsifiable
cutting fluids + Palm Oil 66
4.2 Graph for surface roughness Vs cutting speed for Bacteriostatic Emulsifiable
cutting fluids + Palm Oil 67
4.3 Graph for surface roughness Vs machining time for Bacteriostatic Emulsifiable
(Razif, 2007) 70
4.4 Graph for surface roughness Vs cutting speed for Bacteriostatic Emulsifiable
(Razif, 2007) 71
4.5 (a) Surface texture of mild steel before turning process for speed 185 rpm 72 4.5(b) Surface texture for cutting speed 185 rpm 72 4.6 (a) Surface texture of mild steel before turning process for speed 340 rpm 73 4.6 (b) Surface texture for cutting speed 340 rpm 73 4.7 (a) Surface texture of mild steel before turning process for speed 425 rpm 74 4.7 (b) Surface texture for cutting speed 425 rpm 74 4.8 (a) Surface texture of mild steel before turning process for speed 625 rpm 75 4.8 (b) Surface texture for cutting speed 625 rpm 75 4.9 Comparison graph for cutting speed 185 rpm 77 4.10 Comparison graph for cutting speed 340 rpm 78 4.11 Comparison graph for cutting speed 425 rpm 79 4.12 Comparison graph for cutting speed 625 rpm 80
4.13 Comparison graph for 5 minutes 81
4.14 Comparison graph for 7.5 minutes 82
4.15 Comparison graph for 10 minutes 83
LIST OF TABLES
2.1 Suitable types of cutting fluids depend to materials machining operation 18 2.2 ISO-Recommended Roughness Values and Grade Numbers for the specification
of surface roughness 39
3.1 Experiment design 58
4.1 Surface roughness experiment data using Bacteriostatic Emulsifiable Cutting
Fluids mixed with palm oil 63
4.2 Specific result of surface roughness value obtained from Bacteriostatic Emulsifiable cutting fluids mixed with palm oil experiment 65 4.3 Specific result of surface roughness value obtained from Bacteriostatic
Emulsifiable experiment (Razif, 2007) 69
LIST OF ABBREVIATIONS, SIGNS, AND SYMBOLS
FKP - Fakulti Kejuruteraan Pembuatan HSS - high speed steel
in - inch
ipr - inch per revolution
ISO - International Organization for Standardization KeV - kilo electron volt
kPa - kilo Pascal
mm - millimetre (metric unit) psi - per square inch
PSM - Projek Sarjana Muda
Ra - arithmetic mean value (roughness average) Rpm - revolution per minute
Rq - root mean square average SEM - scanning electron microscopy sfpm - square feet per minute
UTeM - Universiti Teknikal Malaysia Melaka
CHAPTER 1
INTRODUCTION
1.1 Introduction
Generally, cutting fluids usage in machining are vital because they help in dissipating heat generated by metal cutting process, reduce friction and wear, thus improving tool life and the surface finish of the workpiece, reduce forces and energy consumption, flush away the chips from the cutting zone. It also prevents the chips from interfering with the cutting process, particularly in operations such as drilling and tapping and protects the machined surface from environmental corrosion.
However, the cutting fluid itself are environmentally unfriendly, costly, and
potentially toxic. The recent shift to dry cutting has not completely solved the
problem. Dry cutting increases energy costs, increases per part costs, and requires a
capital investment that is too large for most machine shops. This approach is a
cost-effective or practical way to eliminate the use of environmentally unfriendly cutting
fluids. They either require oils of questionable effectiveness or flow,
high-pressure systems that would be costly and difficult to implement in a production
environment.
Due to the many problems regarding to the healthy and the environmental issues, the
vegetable oil such as the soybean oil and palm oil are finding their way into
lubricants for industrial applications. It is seems that it is the suitable replacements of
the conventional coolants. These oils such as palm oil, indeed offer significant
Many techniques can be used to determine the performance of coolant and its effect to environment, human and productivity. We choose to compare the performance between only environmental friendly coolant and environmental friendly coolant mixed with palm oil on the value of the surface roughness obtained on the machined specimen and hopefully we can get the answer to the problems occurred in cutting fluids issue.
1.2 Problem Statement
Regarding to this project, we found that a few problems occurred in the process of selecting the right cutting fluid to be used. Therefore, solutions need to be found to solve the problems below:
a. Very little study on the development of palm oil into metalworking fluids lead to an unclear status of palm oil usage in machining operation.
b. Vegetable oil and soybean oil have been tested in machining and good result obtained. The cost of making those oils is quite expensive. In reducing the cost of production, cheaper natural source need to be develop.
1.3 Objectives
The objectives of this research are:
a. To carry out experiment using oil based coolant and combination of oil based
coolant with palm oil in turning operation and evaluate the surface finish
performance by analyzing the surface roughness of the specimen machined.
a. 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
finish
b. To determine whether palm oil is suitable for the machining operation and
1.4 Project Scope
Basically, this project conducted to compare the performance between oil based coolant and combination of oil based coolant with palm oil in turning operation and the performance is evaluated from the surface finish of the specimen machined. High speed steel (HSS) is used as a cutting tool and the material for turning operation is mild steel (AISI 1045). The process is performed under different parameters such as feed rate, cutting speed, depth of cut and cutting time. This study will be focusing on the surface finish obtained from the machining using two different types of coolants performance. Samples from the machining operation will be analyzed using surface roughness tester and metallurgy microscope. The value of surface roughness from the specimens will be recorded for making comparison for the both cutting fluids used. Discussions are made under the result obtain and the most suitable coolant to be used will be stated in conclusion made.
1.5 Limitation of Scope
CHAPTER 2
LITERITURE REVIEW
2.1 Introduction
In this chapter, brief explanations about related topics on this research are revealed. This chapter will discuss about cutting fluids and criteria which are related to cutting fluids fundamentals which is suitable to be a revision for this study. Also being discussed in this chapter is about lathe machine and its operation such as turning and also about surface metrology. All of the fundamentals about related topics are taken from previous studies from journals, books and articles.
2.2 Introduction to Cutting Fluids
Cutting fluids are widely used throughout industry in many machining operations such as milling, grinding, boring, and turning. Large machining facilities use central fluid systems with capacities as high as 760 000 liters, and it is estimated that over 380 million liters of metalworking fluids are used each year (Gunther & Sutherland, 1999).
Depending on the type of machining operation, the cutting fluid needed may be a coolant, a lubricant, or both. The effectiveness of cutting fluids depends on a number of factors, such as the type of machining operation, tool and workpiece materials, cutting speed, and the method of application. Water is an excellent coolant and can reduce effectively the high temperatures developed in the cutting zone. However, water is not an effective lubricant; hence it does not reduce friction. Furthermore, it causes the rusting of workpieces and machine-tool components. On the other hand, as we have seen, effective lubrication is an important factor in machining operations (Kalpakjian & Schmid, 2001).
The need for a cutting fluid depends on the severity of the particular machining operation, which may be defined as the level of temperatures and forces encountered, the tendency for built-up edge (BUE) formation, the ease with which chips produced can be removed from the cutting zone, and how effectively the fluids can be applied to the proper region at the tool-chip interface. The relative severities of specific ma-chining processes in increasing order of severity are: sawing, turning, milling, drilling, gear cutting, thread cutting, tapping, and internal broaching (Kalpakjian & Schmid, 2001).
