Oil Particle Analysis Using Fourier Transform Infrared Spectroscopy.

(1)

OIL PARTICLE ANALYSIS USING FOURIER

TRANSFORM INFRARED SPECTROSCOPY

NURUL ASYIKIN BINTI

ADENAN

(2)

'.I1 p.

UNIVERSTI

TEKNIKAL

MALAYSIA MELAKA

(UTeM)

Oil Particle Analysis Using Fourier Transform

Infrared Spectroscopy

Report submitted in accordance with the partial requirements of the Universti Teknikal Malaysia Melaka (UTeM) for the Bachelor of Manufacturing

Engineering (Material Engineering)

NURUL ASYIKIN

BINTI

ADENAN

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UTeM Library (Pind.112007)

UNiVERSlTl TEKMIKAL MALAYSIA MELAKA

JUDUL: O I L PARTICLE ANALYSIS USING FOURIER ---- TRANSFORM INFRARED

SPECTROSCOPY.

SESl PENGAJIAN : 2004/2008

Says - NURUL ASYIKIN BINTI ADENAN

mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di Perpustakaan Universiti Tekni kal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Mataysia Melaka

.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan

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(Mengandungi maklumat yang berdarjah keselamatan SULIT _{atau kepentingan Malaysia yang termaktub di dalam}

AKTA RAHSIA RASMl 1972)

' TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasilbadan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

(TANDATANGAN PENULIS)

Pensyerah Alamat Tetap: 295, PENGKALAN LEBN MAN, Cop Rasmi: FekulZ [email protected] PembuaBn

08000, S m G A I PETANI, Univers~ti Tekntnal Malaysia Melaka

KEUAH Karung Derkunci _{75450 M c ~ K ~}1'200, Ayer Keroh

Tarikh: 10 MAY 2008 Tarikh: 20 APRIL 2008

' Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM)

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan

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UNlVERSITl TEKNIKAL MALAYSIA MELAKA

Karung Serk~mci 1200, Ayer Keroh, 75450 Melaka

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

Email : [email protected]

FAKULTI KEJURUTERAAN PEMBUATAN

Rujukan Kami (Our Ref) :

Rujukan Tuan (Your Ref):

10 May 2008

Pustakawan

Perpustakawan Universiti Teknikal Malaysia Melaka UTeM, No 1, Jalgn TU 43,

Taman Tasik Utama, Hang Tuah Jaya, Ayer Keroh, 75450, Melaka.

Saudara,

PENGKELASAN TESlS SEBAGAI SULITlTERHAD

-

TESlS SARJANA MUDA KEJURUTERAAN PEMBUATAN (BAHAN KEJURUTERAAN): NURUL ASYlKlN BINTI ADENAN

TAJUK: OIL PARTICLE ANALYSIS USING FOURIER TRANSFORM INFRARED SPECTROSCOPY

Sukacita dimaklumkan bahawa tesis yang tenebut di atas bertajuk "Oil Particle Analysis Using Fourier Transform Infrared Spectroscopy" mohon dikelaskan sebagai terhad untuk tempoh lima (5) tahun dari tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomenialkan di masa hadapan.

Sekian dimaklumkan. Terima kasih.

"BERKHIDMAT UNTUK NEGARA KERANA ALLAH"

Yang benar,

...

MOHD. ASYADI' AZAM BIN MOHD. ABlD Pensyarah,

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APPROVAL

This PSM submitted to the senate of UTeM and has been as partial fulfillment of the

requirements for the degree of Bacheior of Manufacturing Engineering (Materials

Engineering). The members of the supervisory committee are as follow:

(Main Supervisor: Mohd. Asyadi 'Azam bin Mohd. Abid)

Peqsyarah

Fakulti Kejuruteraan Pernbuabn Universiti Tekn~ka~ Malaysia Melakp

Karung Berkurrct 1260, Ayer K e M .

75458 Melaka

...*..,...,...

Co-Supervisor

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ABSTRACT

The purpose of doing this project is to study the oil being used in stamping machine at

Miyazu is the main cause of dings and dent of the stamped automotive parts. The FT-iR

spectrum of clean and used oil is analyzed using the difference spectroscopy method to

pinpoint the impurities, oxidation and water content level which is identified as the main

cause of cleaning degradation. This achieved through a series of systematic experiments

through following studies. The studies of oil used in production line tools is covered the

properties of clean oil. The results are beneficial in order to understand the original

characteristics of materials used in this investigation. In order to determine the sources

of the contaminant, several aspects of the mechanism of oil flow, oil recycle and

cleaning actions and is studied in details. The results are the important input for oil

particle analysis. The oil quality is investigated by using FTIR Spectroscopy

equipments. The samples of clean oil and used oil in four stage process at upper die and

lower die stamping machine area is analyzed of water content in oil, soot loading

(resulting in increased wear and viscosity), oxidation, nitration, antiwear components,

sulfating (sulfate by-products), and ethylene glycol contamination. The result is

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ABSTRAK

Projek ini adalah bertujuan untuk mengkaji minyak yang digunakan dalam mesin

penghentakan di kilang Miyazu(M) Sdn.Bhd. yang berkemungkinan menjadi punca

utama menyebabkan hasil pengeluaran automotif tersebut mempunyai kesan lekuk.

Spektnun FT-iR untuk minyak yang belum digunakan dan minyak yang telah digunakan

dianalisa menggunakan beberapa kaedah untuk mengkaji bendasing, pengoksidaan, dm

kandungan air yang menyebabkan kurangnya keberkesanan dalam proses pembersihan.

Ini dapat dicapai melalui beberapa siri sistematik eksperimen dalam kajian. Kajian

terhadap minyak yang digunakan di bahagian pengeluaran ini adalah meliputi kajian

terhadap kandungan yang terdapat dalam minyak tersebut. Hasil dari _{kajian tersebut}

adalah penting untuk memaharni dan mengetahui kandungan asal dan sifat dalam

minyak yang sedang dianalisis. Dalarn usaha untuk menentukan punca sebenar yang

menyebabkan pencemaran terhadap rninyak tersebut, beberapa aspek telah diambilkira

untuk dianalisa. Aspek-aspek tersebut adalah seperti mekanisma kadaran rninyak, kadar

pertukaran minyak

dan

_{pembersihan di}_kawasan_{pengeluaran tersebut. Kuditi minyak}

pula dikenalpasti dengan menggunakan peralatan FTIR Spectroscopy. Contoh minyak

sebelum digunakan dan selepas digunakan di empat kawasan atas acuan

dan

_bawah

acuan proses mesin hentakan ini dianalisa kandungan air, jelaga (yang mempengaruhi

kelikatan), pengoksidaan, penitratan, bahan pengelak kehausan, pengsulfuran dari

produk clan pencemaran bahan ethylene glycol. Keputusan dari ujikaji ini adalah penting

untuk menentukan punca utama ke atas kurangnya keberkesanan proses pembersihan

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DEDICATION

For My beloved father and mother.

Thank you very much for your continuous support and eflort towards the publication of

this thesis.

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ACKNOWLEDMENTS

Bismillahirrahmanirrahim

...

Firstly, I would like to convey my gratitude towards the Al-Mighty for giving me the

strength and willingness to complete Final Year Project. I am indebted to many people

in this dissertation effort. First and foremost, I would like to express my sincere

gratitude and appreciation to Mr. Mohd. Asyadi' Azam Bin Mohd.Abid, my supervisor,

Mr. Fairuzdimin, my co-supervisor 1, and Mr. Mohd Hazley Bin Abu Bakar, my co-

supervisor 2 for their advice, support and tireless effort, who guided me to this end in

this area that I like most: oil particle analysis using Fourier transform infrared

spectroscopy. I deeply appreciate for the countless hours spent by them all on this

dissertation since it was first started as a pilot study. Them refinement of this

dissertation is invaluable.

An extended note of appreciation is in order for Madam Intan Shahrida and h4R.Haidir

for his constructive comments and suggestions as my panel presentation.

Special thanks and appreciation are due to my parent, Mr. Adenan

Bin

Ahmad and

Madam Siti Meriam Binti Md.Isa for their sacrifice, encouragement, understanding and

assistance in the dissertation effort. Acknowledgement of appreciation also goes to my

friends for their patience and support. Without all of you, I cannot achieve what I have

today.

Thank

you agqin.

Wassalarn.

..

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2. LITERATURE REVIEW

2.1 Product Cleaning System

2.1.1 Metal Stamping Process

2.1.2 Metal Stamping Operation

2.1.3 Metal Stamping Technique

2.1.4 Metals used in stamping process

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2.2 Oil Particle Analysis

2.2.1 Oil Oxidation

2.2.2 The Why and How of Oxidation Testing

2.2.3 The Effect of Oxidation on Lubricant Properties 14

2.2.4 Oil Analysis Indications of Lubricant Oxidation 15

2.2.5 The Signs of Trouble 16

2.2.6 Proactive Maintenance and Off-line Oil Filtration Stamping Press 18

2.2.7 The Limitations of Oil Analysis 18

2.2.8 Causes of Wear 19

2.2.9 Why Particles Need to Be Monitored and Controlled 20

2.2.9.1 Proactive Maintenance 20

2.2.9.2 Managing Particle Contamination 2 1

2.2.9.3 Particle Counting - The "Invisible" Filter 22

2.1.1 0 Conclusion of Lubricant Oxidation 24

2.2.1 1 Normal Equipment and Method for Oil Particle Analysis

2.2.1 1.1 THY-1 8F intellectualized Oil Quality Analyzer 25

2.2.1 1.2 THY-21AIntellectualized Oil Quality Analyzer 26

2.2.1 1.3 THY-XW Portable Type Octane Analyzer 26

2.3 Introduction to FTIR Spectroscopy 27

2.3.1 Operation of FTIR 28

2.3 -2 Spectroscopy

2.3.3 Origin of Spectra

2.3.4 Instruments

2.3.5 Methods and Applications 3 1

2.3.6 Attenuated Total Reflectance

2.3.7 Signal-Averaging

2.3.8 AdvanQges

2.3.9 Computers

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2.3.10 Spectra

2.3.1 1 Troubleshooting of FTIR Process

3. METHODOLOGY

3.1 Introduction

3.2 Specimen/Material and Equipment

3.2.1 Lubricant Oil Sample

3.2.2 Fourier Transform Infrared (FTIR) Spectroscopy

3.2.3 EssentialFTIR Software

3.3 FTIR Analysis

3.3.1 EssentialFTIR

3.3.2 Setting vp Widows Login

3.3.3 Setting up PerkinElmer Login

3.3.4 Viewing data files

3.3.5 Browse the Library

3.3.6 Search

a

Spectrum

3.4 Flow Process to perform this project

4. RESULT AND DISCUSSION

4.1 Introduction 49

4.2 Observation of FT-Ir Spectrum using ATR method for oil sample

of clean, F-Line, D-Line, G-Line, H-Line, J-Line and Blank 50

4.3 Observation of FT-Ir Spectrum using ATR method for sample of

clean oil and used oil at G-Line Miyazu (M) Sdn. Bhd. 54

4.3.1 Observation of sulfating (sulfate by-products) in oil lubricant

at upper die and lower die stamping machine. 56

4.3.2 Observation of water content in oil lubricant at upper die and

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4.3.3 Observation of soot loading (resulting in increased wear and

viscosity) in oil lubricant at upper die and lower die stamping

machine. 61

4.3.4 Observation of oil oxidation at upper die and lower die

stamping machine. 63

4.3.5 Observation of nitration in oil lubricant at upper die and

lower die stamping machine. 65

4.3.6 Observation of antiwear components in oil lubricant at upper

die and lower die stamping machine. 67

5. CONCLUSION AND SUGGESTIONS

5.1 Conclusion

5.2 Suggestions

REFERENCES 71

APPENDICES

ASTM E 2412

Result clean oil scans using FTIR Spectroscopy

Result G1 LD scans using FTLR Spectroscopy

Result G2 LD scans using FTIR Spectroscopy

Result G3 LD scans using FTIR Spectroscopy

Result G4

L q

scans using FTIR Spectroscopy

Result G1 UD scans using FTIR Spectroscopy

Result G4 UT) scans using FTIR Spectroscopy

...

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LIST OF FIGURES

Metal Stamping Machine

The metal stamping machine that used for stamping process

Progressive (punch and Blanking) die with strip and punching

FTIR Spectroscopy

The basic idea of the FTIR operation

A single reflection diamond ATR accessory

Schematic of p typical attenuated total reflectance cell

A single reflection diamond ATR crystal

Castrol oil used in stamping machine

Sample clean Castrol is collected to test by using FTIR Spectroscopy

Sample used oil at Line D, F, G, H, J and Blank is collected to

test by using FTIR Spectroscopy

Sample used oil at G-Line (upper and lower die)

The sample of used oil is taken by using cotton buds for testing

FTIR Spectroscopy

EssentialFTIR Software

The start button on the monitor screen

The 'File Browser' from the menu bar

The 'File Browser' menu at the bottom of the screen.

A screen of EssentialFTIR Library

The search spectrum menu

The graph of the scan with the peak number

The graph without the peak number

The 111 view of the EssentialFTIR software

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Graph for sample of clean oil, used oil at D-Line, F-Line,

G-Line, H-Line, J-Line and Blank Line.

Histogram graph of probability hit for each sample.

Scatter diagram graph of probability hit for each sample.

The graph for FT-Ir Spectrum using ATR method for sample of

clean oil and used oil at lower die in G-Line Miyazu OM) Sdn. Bhd.

Graph for FT-Ir Spectrum using ATR method for sample of clean

oil and used oil at upper die in G-Line Miyazu (M) Sdn. Bhd.

Graph result for sulfating in oil lubricant at upper die stamping machine.

Graph result for sulfating in oil lubricant at lower die stamping machine.

Graph for water content in oil lubricant at upper die stamping machine.

Graph for water content in oil lubricant at lower die stamping machine.

Graph for ethylene glycol contaminant in oil lubricant at upper die

stamping machine area.

Graph for ethylene glycol contaminant in oil lubricant at lower die

stamping machine area.

Graph comparison for oil analysis of the value soot loading in all

samples oil taken at upper die and lower die fiom G-Line by using

FTIR spectroscopy.

Graph result scanning by FTIR Spectroscopy of oil oxidation at

upper die area stamping machine.

Graph result scanning by FTiR Spectroscopy of oil oxidation at

lower die area stamping machine.

Graph result for nitration in oil lubricant at upper die stamping machine.

Graph result for nitration in oil lubricant at lower die stamping machine.

Graph result for antiwear in oil lubricant at upper die stamping machine.

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LIST OF TABLES

Percentage silicate, ultrapol 2 and 3 black polishing media in

sample of clean oil, used oil at D-Line, F-Line, G-Line, H-Line,

J-Line and Blank Line.

Percentage arsenic brass 25, jade, inhgold coating and potassium

bromide in sample of clean oil, used oil at D-Line, F-Line, G-Line,

H-Line, J-Line and Blank Line. 5 1

Type of sample oil analysis in G-Line with the value of transmittance

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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCALTURE

FTIR

-

IR

-

(M) Sdn.Bhd.

-

(CADICAM)

-

Utern

EDM

TAN

-

EDX

-

Sc

-

Det

-

ATR .

-

SNR

-

GI UD

-

G2UD

-

G3 UD

-

G4 UD

-

G1 LD

-

G2 LD

-

G3 LD

-

G4 LD

-

Fourier Transform Infrared Spectroscopy

I n b e d

Malaysia Sendirian Berhad

Computer-aided design and manufacturing

Universiti Teknikal Malaysia Melaka

Electrical Discharge Machining

Total Acid Number

Energy Dispersive X-ray Spectroscopy

Source

Detector

Attenuated Total Reflectance

Signal-to-noise

First stage at upper die

Second stage at upper die

Third stage at upper die

Fourth stage at upper die

First stage at lower die

Second stage at lower die

Third stage at lower die

Fourth stage at lower die

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CHAPTER 1

INTRODUCTION

1.1 Background of Project

In this project, several samples of oil taken from the industry will be studied in

details using FTIR facilities provided by the university. Several lecturers and students

will be involved in analyzing and presenting the data from the analysis. The results

could be beneficial to the industry in understanding the quality of the materials used in

the production line. The university can employ these opportunities to enhance the

knowledge and skills of the students by experiencing real industry based projects.

For this research, I need to study about the metal stamping process, the oil

particle analysis and also the contamination that involve in the oil that they used in order

to help the industry to prevent the defect from occurring again.

In order to start progress with the oil particle analysis, I need to study about the

product cleaning system in stamping process that involve in the industry to gain

knowledge about the metal stamping process and the defect that occur in the metal

stamping process. By doing this study, I can define how the defect occur and what make

the defect occur in the process.

When the contamination and the sources of how the contamination occurs had

been identified, its can make improvement to prevent it from occur again. By doing this

research, hopefully it can help the industry in order to reduce the defect of the product

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[image:19.603.200.449.114.318.2]

1.1.1 Background of Metal Stamping Machines

Figure 1.1 : Metal Stamping Machine

Metal stamping is a process where the sheet of metal is stamp for manufacturing

metal part according to the design that had be done. A metal alloy sheet is used as the

stock and the stock is either stamped on a press using dies and punches or drawn into

shapes on hydraulic deep drawing machines. Common product produce are automobile

parts, electronic parts, aerosol spray can and also household ware product such as pots

and pans. In metal stamping process, dies and punches are used to cut the metal into the

required shape which is called male components for the punches and the female

component for the dies. Press machine tools are used in the stamping process. This metal

stamping is use oil as lubricant for product cleaning system in dies and punches for

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1.12 Background of Oil Particle Analysis

Oil particle analysis is an analysis to measurement of all particles that have

accumulated and contaminant within oil, including those metallic and non-metallic,

fibers, dirt, water, bacteria and any other kind of debris. It is most useful in determining

fluid and system cleanliness with a fluid viscosity.

Contamination can be defined as any unwanted substance or energy that enters or

contacts the oil. Contaminants can come in a great many forms; some are highly

destructive to the oil, its additives, and machine surfaces. It is often overlooked as a

source of failure because its impact is usually slow and imperceptible yet, given time;

the damage is analogous to eating the machine up from the inside out. While it is not

practical to attempt to totally eradicate contamination from in-service lubricants, control

of contaminant levels within acceptable limits is accomplishable and vitally important.

Particles, moisture, soot, heat, air, glycol, fuel, detergents, and process fluids are

all contaminants commonly found in industrial lubricants and hydraulic fluids. However,

it's particle contamination that is widely recognized as the most destructive to the oil

and machine. This explains why the particle counter is the most widely used instrument

in oil analysis today. And, the central strategy to its success in reducing maintenance

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1.13 Background of FTIR

FTIR (Fourier Transform Inflated) Spectroscopy is an analysis technique that

provides information about the chemical bonding or molecular structure of materials. It

is used in failure analysis to identify unknown materials present in a specimen, good to

bad sample comparison and comparison of materials from different lots or vendors.

Fourier transform spectroscopy is a measurement technique whereby spectra are

collected based on measurements of the temporal coherence of a radiative source, using

time-domain measurements of the electromagnetic radiation or other type of radiation. It

can be applied to a variety of types of spectroscopy including optical spectroscopy,

inlimed spectroscopy(IR), nuclear magnetic resonance, and electron spin resonance

SpectrO='PY.

1.1.4 Background of Miyazu (M) SDN. BHD.

Miyazu (Malaysia) Sda Bhd., an anchor Class A large dies and moulds producer

in Malaysia, is a collaboration between Proton (5 1 %), Miyazu Seisakusho (Japan) (34%)

and Sojitz Corporation (15%). From a tooling shop in PROTON Shah Alam then

designing and engineering the stamping dies for various PROTON models, the company

expanded its operations by localizing the production of dies for PROTON W i Perdana

and GEN2 models between 1 994 and 2003.

In 2004 Miyazu went on to engineer and localize all the body parts for the

PROTON Savvy, with a total of 712 dies. It subsequently produced dies for PROTON

Persona and began exporting dies to Takao Thailand and Mazda in 2005 and 2006

respectively.

In April 2006, Miyazu expanded its portfolio to include stamping parts

production and thus commenced the implementation of TPS in collaboration with

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standards. In April of this year, Miyazu launched an A-Class Tooling Plant in PROTON

City, Tanjung Malirn, further transforming the company into a key automotive tools

manufacturer in the ASEAN region.

Miyazu's new tooling plant marks Malaysia's entry into the highly specialized

and technology intensive industry of designing, engineering and manufacturing of

automotive tools. Miyazu Malaysia's position as an anchor Class A large dies and

moulds producer is expected to pave the way for the formation of Tool Maker

clusters. This in turn _{will result in the creation of an even bigger supporting industry}

such as casting, hard chroming, machining, production of dies components, logistics and

calibration, to name a few.

The company has a paid up capital of RM17.5 million with strength of 250

personnel based at its Class A automotive tooling plant at the PROTON Tanjung Malirn

Vendor Park in Tanjung Malim. The 3,600-square metre plant, located on a 10.5-acre

site, houses state-of-the-art design, engineering, machining and finishing facilities which

include computer-aided design and manufacturing (CADICAM) applications, and

double-column, coordinate-measuring and pressing machines.

These are critical tools required to design, engineer and produce the dies and

moulds for the production of automobile components such as roof, bonnet, fender,

dashboard, and door, side and other body panels. At full operational capacity, Miyazu

Malaysia, together with its technology suppliers and business partners, is able to

manufacture and 1oc;flize over 400 dies annually, thus reducing dependency on foreign

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1.2 Problem Statement

Several studies in production line show that the dusty environment of the

industry causes a lot of problems to the quality of the product. The deposited dust causes

defects on the surface of the stamped parts. In order to remove the deposited dust,

several cleaning actions have been employed to clean the product using specialized oil.

The oil have been used repetitively and recycled to clean numbers of parts. Up to several

time of usage, the oil has to be changed to maintain the cleaning quality. At the moment,

the limited studies to detect the level of contaminant for each cycle of oil. This research

emphasizes the analysis of contaminant level of oil based on the cycles or times of usage

using FTIR. The study involves the comparison between 'good' and 'contaminated' oil

and impurities detection of the oil compositions. This research will enhance the

information of the leyel of oil contaminants in each cycle. The results of the study also

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1.3 Objective of Project

It is compulsory for an UTeM student to pass the "Project Sarjana Muda" before

being awarded the degree. The overall objective of this project is to determine if the oil

being used by the stamping line at Miyazu is the main cause of dings and dent of the

stamped automotive parts. The FTiR spectrum of clean and used oil will be analyzed

using the difference spectroscopy method to pinpoint the impurities, oxidation and water

content level which has been identified as the main cause of cleaning degradation. This

will be achieved through a series of systematic experiments through following studies:

13.1 To understand the characteristics of oil used in production line:

The studies of oil used in production line tools will cover the properties of clean

oil. The results would be beneficial in order to understand the original

characteristics of materials used in this investigation.

1.3.2 To understand the mechanisms of cleaning actions in production line:

In order to determine the sources of the con taminant, several aspects of the

mechanism of oil flow, oil recycle and cleaning actions and will be studied in

details. The results would be the important input for oil particle analysis.

13.3 To analysis the oil quality using

FTIR

spectroscopy:

The oil quality will be investigated by using

FTIR

Spectroscopy equipments. The

samples of clean oil and used oil in four stage process at upper die and lower die

stamping machine area is analysis of water content in oil, soot loading (resulting

in increased wear and viscosity), oxidation, nitration, antiwear components,

sulfating (sulfate by-products), and ethylene glycol contamination. The result

would be important to identifjr the main cause of cleaning degradation and part

Oil Particle Analysis Using Fourier Transform Infrared Spectroscopy.