project proposal reference number: 36s be 1836 ... · have been incorporated in the report and this...

Project Proposal Reference Number: 36S_BE_1836

Experimental Studies on Cutting Parameters during Drilling

Operation of Mild Steel Using Eco-Friendly Vegetable Oil as

Cutting Fluid

A Project sponsored by

KARNATAKA STATE COUNCIL FOR SCIENCE AND TECHNOLOGY

INDIAN INSTITUTE OF SCIENCE CAMPUS

BENGALURU -560012

In partial fulfilment

Submitted by

M Susmitha 1KG11ME054

Sharan P 1KG12ME043

Under the Guidance of

Dr. Jyothi .P.N

Professor

Dept. of Mechanical Engineering

KSSEM, Bengaluru

Department of Mechanical Engineering

K.S. School of Engineering and Management

No. 15, Mallasandra, off Kanakapura Road, Bengaluru – 560109

2015-16


No. 15, Mallasandra, off Kanakapura Road, Bengaluru-560109


Certificate

This is to certify that the project work entitled Experimental Studies on Cutting

Parameters during Drilling Operation of Mild Steel Using Eco-Friendly Vegetable

Oil as Cutting Fluid is a bonafide work carried out by


Sharan P 1KG12ME043

in partial fulfilment for the award of Bachelor of Engineering in Mechanical

Engineering of Visvesvaraya Technological University, Belgaum, during the year

2013-14. It is certified that all the suggestions indicated during internal assessment

have been incorporated in the report and this thesis satisfies the academic

requirement in respect of project work prescribed for the degree.

_____________________________ Name and Signature of Internal Guide

____________________ Head of the Department

_______________ Principal/ Director


No. 15, Mallasandra, off Kanakapura Road, Bengaluru-560109


Declaration

We,


Sharan P 1KG12ME043

the students of eight semester BE (Mechanical Engineering) declare that the

project entitled Experimental Studies on Cutting Parameters During Drilling

Operation of Mild Steel Using Eco -Friendly Vegetable Oil as Cutting Fluid is

carried out by us at K.S. School of Engineering and Management as a partial

fulfilment of academic requirement of BE in Mechanical Engineering under

Visvesvaraya Technological University. The content in the thesis are original and

are free from plagiarism and other academic dishonesty and are not submitted to

any other University either partially or wholly for the award of any other degree.

Sl. No Reg No. Name of Student Signature with Date

i

Acknowledgement We would like to express our heartfelt thanks to our guide Dr. Jyothi .P .N,

Professor, Department of Mechanical Engineering, KSSEM, Bangalore, who has been our

main Inspiration and Motivation to carry out this project work and who has always been

there for us to clarify our doubts and give her valuable suggestions throughout this project

process.

Our project is incomplete without mentioning the guidance and support lent by

Dr. Shailesh Rao.A, Professor and Head, Department of Mechanical Engineering, in every

possible aspect.

Words fall short to express our gratitude towards Dr. S N Sridhara,

Principal/Director, K S School of Engineering and Management, Bangalore, for his

constant support and guidance throughout our project work.

We would like to thank all the teaching and non-teaching staff of K S School of

Engineering and Management, Bangalore, for supporting us throughout our project process.

Special thanks to our beloved FOREMAN Sir Mr. Manjunath for lending is hand and

helping us in completing our project.

This project would not have been possible if we were not supported by our parents

and friends. They were our source of an inspiration and their support has always been there

morally and financially for us. Thanking them with full heart for their motivation.

We take this opportunity to express our profound gratitude and deep regards to the

Karnataka State Council for Science and Technology, for recognizing the potential in

our project and approving it for the 39th series of student project program.

Words always fail to express the gratitude towards those who have helped in

disguise and we are very much grateful to people who have directly or indirectly helped us

towards the completion of the thesis.

ii

Abstract During machining process, friction between workpiece-cutting tool and cutting tool-chip

interfaces cause high temperature on cutting tool. The effect of this generated heat

decreases tool life, increases surface roughness and decreases the dimensional sensitiveness

of work material. The cutting fluids are used to provide lubrication and cooling effects

between cutting tool and workpiece and cutting tool and chip during machining operation.

Various factors affects the selection of cutting fluid type during machining operation such

as type of work piece materials, cutting tool material and the method of machining

processes. Cutting fluids increase the tool life and improve the efficiency of the production

systems providing both cooling and lubricating the work surface.

Bio lubricant from non-edible vegetable oils have received considerable research

attention in the last decades owing to their remarkable improved tribological characteristics

and due to increasing attention to environmental issues has driven the lubricant industry

toward eco-friendly products from renewable sources. Researches on drilling with bio-oils

(non-edible vegetable oil) based cutting fluids are limited. Therefore, it is necessary to

develop and evaluate performance of NAVBCFs.

In the present work, different non-edible vegetable oils are used as cutting fluid

during drilling of Mild steel work piece. Non-edible vegetable oils, used are Karanja oil

(Honge), Neem oil and blend of these two oils in different proportions (50% Neem & 50%

Karanja, 33.3% Neem & 66.6% Karanja, 66.6% Neem & 33.3% Karanja). The effect of

these cutting fluids on various machining parameters are studied and compared with results

obtained with petroleum based cutting fluids and dry conditions. From the results it is

observed that 50% Neem & 50% Karanja blend has better physical properties compared to

other used. The blend of 50% Neem- 50% Karanja is proved to be best cutting fluid as

cutting force of 169.23N , temperature of tool was 36.2˚C and the temperature of specimen

was 39.1˚C was observed which is very less compared to others. Hardness values obtained

for 50% Neem- 50% Karanja after machining is nearer to base metal hardness before

machining.

iii

Contents

Chapter-1 ................................................................................................................................................... 1

INTRODUCTION ................................................................................................................................. 1

1.1 Machining operations: ......................................................................................................... 1

1.1.1Turning operation: ..................................................................................................... 1

1.1.2 Millingoperation: ...................................................................................................... 1

1.1.3 Drilling operation: ..................................................................................................... 2

1.1.4 Miscellaneous operations .......................................................................................... 2

1.2 Cutting fluids: ...................................................................................................................... 3

1.3 Classification of cutting fluids:............................................................................................ 3

1.3.1 Straight oils: .............................................................................................................. 3

1.3.2 Synthetic fluids: ........................................................................................................ 3

1.3.3 Soluble oil fluids: ...................................................................................................... 3

1.3.4 Semi syntheti cfluids: ................................................................................................ 4

1.4 Pros and Cons of each type of cutting fluid:........................................................................ 4

1.5 Basic functions of cutting fluids: ......................................................................................... 4

1.5.1 Cooling: ............................................................................................................. 4

1.5.2 Lubrication: ........................................................................................................ 4

1.5.3 Corrosion protection: .......................................................................................... 5

1.5.4 Chips Removal ................................................................................................... 5

1.6 The Desirable properties of cutting fluids in general: ......................................................... 5

1.7 Characteristics of cutting fluids: .......................................................................................... 5

1.8 Process effects of using cutting fluids in machining include: ............................................. 6

1.9 Factors to be considered while selecting Cutting Fluids: .................................................... 6

1.9.1 Types of work piece materials: .................................................................................. 6

iv

1.9.2 Types of cutting tool material: ................................................................................... 6

1.10 Reducing adverse effects of Cutting Fluids on Environmental: .......................................... 7

1.10.1 Dry Machining: ....................................................................................................... 7

1.10.2 Minimum Quantity of Lubrication (MQL): ............................................................. 7

1.11 Drawbacks of petroleum based cutting fluids: .................................................................... 8

1.12 Vegetable based cutting fluid: ............................................................................................. 8

1.13 Applications of vegetable oils: ............................................................................................ 9

1.13 Edibleoils: .................................................................................................................. 9

1.13.Non edible oil ............................................................................................................. 9

1.14 Current Status — Non Edible Vegetable Oils: .................................................................... 9

Chapter-2 ................................................................................................................................................. 11

LITERATURE REVIEW .................................................................................................................... 11

Chapter-3 ................................................................................................................................................. 20

EXPERIMENTAL DETAILS ............................................................................................................. 20

3.1 Selection of Bio-Oils: ........................................................................................................ 20

3.1.1 Neem oil: ................................................................................................................. 20

3.1.2 Karanja oil: .............................................................................................................. 21

3.2 Physical Properties: ........................................................................................................... 22

3.3 Equipment used: ................................................................................................................ 23

3.3.1 Cleveland open cup tester: ...................................................................................... 23

3.3.2 Saybolt viscometer: ................................................................................................. 23

3.3.3 CNC Drilling machine: ........................................................................................... 24

3.3.4 Lathe Machine:........................................................................................................ 24

3.3.5 IR Thermometer: ..................................................................................................... 25

3.3.6 Profile Projector: ..................................................................................................... 25

3.3.7 Surface finish tester: ................................................................................................ 26

3.3.8 Hardness testing machine: ....................................................................................... 26

v

3.3.9 Dynamometer Meter: .............................................................................................. 27

3.3.10 Optical Microscope: .............................................................................................. 27

3.4 Experimental procedure and conditions: ........................................................................... 28

Chapter-4 ................................................................................................................................................. 30

RESULTS AND DISCUSSION ......................................................................................................... 30

4.1 Physical Properties of Cutting fluids: ................................................................................ 30

4.1.1 Flash Point and Fire Point: ...................................................................................... 30

4.1.2 Viscosity: ................................................................................................................. 31

4.1.3 Specific Heat: .......................................................................................................... 31

4.1.4 Adhesiveness: .......................................................................................................... 32

4.2 Study of chips: ................................................................................................................... 33

4.3 Surface roughness of machined surface: ........................................................................... 36

4.4 Colour of the chips: ........................................................................................................... 37

4.5 Cutting Force: .................................................................................................................... 38

4.6 Hardness Test: ................................................................................................................... 40

4.7 Temperature of work piece and drill bit during machining: .............................................. 41

4.8 Wear Studies of the Machined work piece surface: .......................................................... 43

4.9 Micro structural Studies: ................................................................................................... 44

4.10 SEM Analysis: ................................................................................................................... 45

Chapter-5 ................................................................................................................................................. 48

CONCLUSION ................................................................................................................................... 48

Scope for future work: ......................................................................................................................... 50

References……………………………………………………………………………………...51

Annexure…………………………………………………………………………………….....53

vi

List of Figures

Fig 1. 1 Turning operation (source: mini-lathe.com) ................................................................................ 1

Fig 1. 2 Milling operation (source: cimindustry.com) .............................................................................. 2

Fig 1. 3 Drilling operation (source: pdf-inc.com) ..................................................................................... 2

Fig 2. 1 Turing Operation (Source:Machinetools.com) .......................................................................... 11

Fig 2. 2 Drilling Operation (Source: mini-lathe.com) ............................................................................. 11

Fig 3. 1 Cleveland open cup tester .......................................................................................................... 23

Fig 3. 2 Saybolt viscometer ..................................................................................................................... 23

Fig 3. 3 CNC Machine ............................................................................................................................ 24

Fig 3. 4 Lathe Machine ........................................................................................................................... 24

Fig 3. 5 IR Thermometer (Source: www.gaussmeter.info) ..................................................................... 25

Fig 3. 6 Profile Projector ......................................................................................................................... 25

Fig 3. 7 Surface roughness tester ............................................................................................................ 26

Fig 3. 8 Hardness testing Machine .......................................................................................................... 27

Fig 3. 9 Drill tool Dynamometer ............................................................................................................. 27

Fig 3. 10 Optical Microscope .................................................................................................................. 28

Fig 4. 1 (a) Method used (b) equation used to measure the Adhesiveness of cutting fluid ..................... 33

Fig 4. 2 Chips formed during drilling operation on Mild steel with different cutting fluids .................. 34

Fig 4. 3 Surface Roughness of the machined surface .............................................................................. 37

Fig 4. 4 Graph showing surface roughness measured on work piece with different cutting fluids and at

dry condition ........................................................................................................................................... 37

Fig 4. 5 Chips formed with different colour with application of different cutting fluid and at dry

condition .................................................................................................................................................. 38

Fig 4. 6 Hardness of specimen before and after drilling with different cutting fluids and at dry condition

................................................................................................................................................................. 41

Fig 4. 7 Graph Showing tool and specimen temperature with different cutting fluids and at dry

condition .................................................................................................................................................. 42

Fig 4. 8 Worn surface of machined Specimen with different cutting fluids and at dry condition .......... 43

Fig 4. 9 Micro structural of specimen obtained using different cutting fluids and at dry condition ....... 45

Fig 4. 10 SEM of specimen obtained using different cutting fluids and at dry condition ....................... 47

vii

List of Tables

Table 1. 1 Pros and cons of cutting fluids ................................................................................................. 4

Table 1. 2 Vegetable oils available in India ............................................................................................ 10

Table 3. 1 Composition of Neem oil ....................................................................................................... 21

Table 3. 2 Composition of Karanja oil .................................................................................................... 21

Table 3. 3 Physical properties of cutting fluids used in this work .......................................................... 22

Table 4. 1 Flash Points and Fire points of different cutting fluids .......................................................... 30

Table 4. 2 Viscosity of different cutting fluids ....................................................................................... 31

Table 4. 3 Specific Heat of different cutting fluids ................................................................................. 32

Table 4. 4 Adhesiveness of different cutting fluids ................................................................................. 33

Table 4. 5 Details of chips formed during drilling operation on Mild steel with different cutting fluids 35

Table 4. 6 Surface Roughness measured on machined surface for different cutting fluids and at dry

condition. ................................................................................................................................................. 36

Table 4. 7 Cutting Force measured with different cutting fluid and at dry cutting condition ................. 39

Table 4. 8 The hardness values of all the specimens before drilling and after drilling operation using

different cutting fluids ............................................................................................................................. 40

Table 4. 9 Temperature measured for tool and work piece with cutting fluid and at dry cutting condition

................................................................................................................................................................. 42

INTRODUCTION

Department of Mechanical Engineering, KSSEM Page 1

Chapter-1

INTRODUCTION

Machining is a process designed to change the size, shape, and surface of a material through

removal of materials that could be achieved by straining the material to fracture or by thermal

evaporation. Machining offers important benefits such as:

a. Excellent dimensional tolerances

b. Sharp corners, grooves, fillets, various geometry

c. Surface finish

1.1 Machining operations:

The three principal machining processes are classified as turning, drilling and milling. Other

operations falling into miscellaneous categories include shaping, planning, boring, broaching

and sawing.

1.1.1 Turning operation:

Turing operations are operations that rotate the work piece as the primary method of moving

metal against the cutting tool. Lathes are the principal machine tool used in turning. Fig 1.1

shows Turning operation.

Fig 1. 1Turning operation (source: mini-lathe.com)

1.1.2 Milling operation:

As shown in Fig 1.2 Milling operations are operations in which the cutting tool rotates to bring

cutting edges to bear against the work piece. Milling machines are the principal machine tool

used in milling.

INTRODUCTION


Fig 1. 2Milling operation (source: cimindustry.com)

1.1.3 Drilling operation:

Drilling operations are operations in which holes are produced or refined by bringing a rotating

cutter with cutting edges at the lower extremity into contact with the work piece. As shown in

Fig 1.3 Drilling operations are done primarily in drill presses but sometimes on lathes or mills.

Fig 1. 3Drilling operation (source: pdf-inc.com)

Cutting speed in drilling operation is generally slow due to two cutting edges of drill

tool. Drilling may affect the mechanical properties of the work piece by creating low residual

stresses around the hole opening and a very thin layer of highly stressed and distributed

material on the newly formed surface. This causes the work piece to become more susceptible

to corrosion and crack propagation at the stressed surface. Heat is generated due to friction

between tool and the work piece. This heat produced can be eliminated by using coolants.

Chips may form long spirals or small flakes, depending on the material, and process

parameters. Cutting fluid is used in ejecting chips. In turning operation as the chip forms

outside cutting fluid doesn’t play important role but in drilling the chip formation takes place

inside the hole where cutting fluid is used to eject the chips. In drilling operation cutting fluids

plays an important role. So, in the present work, different non-edible vegetable oils are used as

cutting fluids.

1.1.4 Miscellaneous operations:

Miscellaneous are operations that may not be machining operations in that they may not be

swarf producing operations but these operations are performed at a typical machine tool.

INTRODUCTION


1.2 Cutting fluids:

Cutting fluid, as a component of machining industry, has been introduced and applied over 100

years. Cutting fluids are used in metal machining for a variety of reasons such as improving

tool life, reducing work pieceand thermal deformation, improving surface finish and flushing

away chips from the cutting zone.

1.3 Classification of cutting fluids:

Practically cutting fluids are classified into four categories:

a. Straight oils

b. Soluble oils

c. Semi synthetic fluids

d. Synthetic fluids

1.3.1 Straight oils:

Straight oils are non-emulsifiable. These oils in undiluted form are used in machining

operations. 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 phosphorous. Straight oils provide the best lubrications and poor cooling

characteristics among cutting fluids.

1.3.2 Synthetic fluids:

Synthetic fluids are formulated from alkaline inorganic and organic compounds along with

additives for corrosion inhibition. They are generally used in a diluted form. Synthetic fluids

provide the best cooling performance among all cutting fluids.

1.3.3 Soluble oil fluids:

Soluble oil fluids when mixed with water form an emulsion. The concentrate consists of

emulsifiers and base mineral oil to help produce a stable emulsion. They provide good

lubrication and heat transfer performance. They are the least expensive among all cutting

fluids.

INTRODUCTION


1.3.4 Semi synthetic fluids:

Semi synthetic fluids are combination of soluble oil fluids and synthetic fluids. They have

characteristics common to both types.

1.4 Pros and Cons of each type of cutting fluid:

Table 1. 1Pros and cons of cutting fluids

Cooling Lubrication Corrosion

protection

Chip Removal

Straight oils P G G M

Soluble oils M G M M

Synthetic fluids G M G M

Semi synthetic

fluids

G G G M

Good (G)-Moderate (M)-Poor (P)

Table 1.1 Pros and Cons of different types of cutting fluids based on their cooling, Lubrication,

Corrosion and Chip removal properties.

1.5 Basic functions of cutting fluids:

The basic functions of cutting fluids include the following four considerations: cooling,

lubrication, corrosion protection and chip removal.

1.5.1 Cooling:

It is known that the energy generated in metal cutting operation both through deformation and

the sliding friction appears to be thermal energy or heat. This high temperature can usually

shorten the fool life, cause an undesirable surface finish and bring down the cycle time due to

the reduction of cutting speed. This cutting fluid acts as coolant and reduces the heat generated.

1.5.2 Lubrication:

It is believed that due to high pressure and relatively high temperature in most cutting

operations, liquid film cannot be sustained along tool/work piece interface for all the time.

Thus the conditions in a typical cutting process are believed to approach boundary lubrication.

This can be achieved by cutting fluids.

INTRODUCTION


1.5.3 Corrosion protection:

A good cutting fluid protects the work piece from corrosion damage.

1.5.4 Chip removal:

The fourth major function of cutting fluid in machining process is to remove chips from the

cutting zone. And the fluid will also prevent the machined surface from being scratched by

chips.

1.6 The Desirable properties of cutting fluids in general:

a. High thermal conductivity for cooling

b. Good lubricating qualities

c. High flash point should not entail a fire hazard

d. Must not procedure a gummy or solid precipitate at ordinary working temperatures

e. Be stable against oxidation

f. Must not promote corrosion or dislocation of the work material

g. Must afford some corrosion protection to nearly formed surfaces

h. The components of the lubricant must not become rancid easily

i. No unpleasant odor must develop from continued used

j. Must not cause skin irritation or contamination

k. A viscosity that will permit free flow from the work and dripping from the chips.

1.7 Characteristics of cutting fluids:

A good cutting fluid could be listed as:

a. Good lubricating qualities to reduce friction and heat generation

b. Good cooling action to dissipate the heat effectively that is generated during machining

c. Effective anti-adhesion qualities to prevent metal seizure between the chip and the rake

face

d. Good wetting characteristics which allow the fluid to penetrate better into the contact areas

as well as in the cracks.

e. Should not cause rust and corrosion of the machine components

f. Relatively low viscosity fluids to allow metal chips and dirt to settle out

g. Resistance to rancidity and to formation of a sticky or gummy residue on parts or machines

h. Should be economical in use, filter and dispose.

INTRODUCTION


1.8 Process effects of using cutting fluids in machining include:

a. Longer tool life

b. Reduced thermal deformation of work piece

c. Better surface finish

d. Ease of chip and swarf handling

1.9 Factors to be considered while selecting Cutting Fluids:

1.9.1 Types of work piece materials:

Cutting fluids used, should provide easy machining operation in all materials. Ferrous metal

are brittle in nature and hence during machining they break into small size chips. The friction

between cutting tool and chip is less due to small size chip formation. It was proposed that

using emulsion cutting fluids increases surface finish quality and prevents dust formation

during machining. During machining operation of, generally the high pressure containing and

additive cutting fluids are used. In stainless steel machining, high pressure cutting oils should

be selected. Work-hardening properties in some steels would cause some problems during

machining operation. For machining of heat resistant and difficult-to-cut steel alloys, water

based cutting fluids are preferred, because temperature becomes higher in cutting area. During

machining of aluminium and aluminium alloys, high temperatures do not occur Waterless

cutting fluids prevent the formation of ―built up edge‖, however this type of cutting fluids must

be non-active. Machining of copper and copper alloys poses similar problems. The application

of emulsion cutting fluids or thin mineral oils should be selected for copper and copper based

alloys machining. High pressure additive cutting oils are preferred for brass machining. In the

machining of nickel and nickel alloys, the machining operation should be carried out as dry or

using cutting fluids. Higher cutting speeds and feed rates should be selected when cutting

fluids are used in the machining of these materials. Generally sulphured mineral oil as cutting

fluid is preferred.

1.9.2 Types of cutting tool material:

The other influential parameter for selection of cutting fluid in machining processes is the

cutting tool material. Different cutting tool materials are commercially available for carrying

out different machining operation. High speed steel cutting tools can be used with all type of

cutting fluids. However waterless cutting fluids are preferred when difficult-to-cut materials

INTRODUCTION


are machined. In case of the tungsten carbide (WC) cutting tools application, more cooling

characteristics from cutting fluids are required. This is because of high generated heat in the

interface of cutting tool and work piece material. The negative effect of generated heat during

machining with WC cutting tools causes rapid tool wear. Hence toll life will be shorter and

surface finish quality falls.

1.10 Reducing adverse effects of Cutting Fluids on Environmental:

1.10.1 Dry Machining:

Dry machining means that no cutting fluid is used during process. For economic as well as

environmental reasons machining process is carried out without any cutting fluid. Some work

piece materials presents many problems during dry machining like Aluminium, which is a soft

material. Dry machining of Aluminium induces influences on the surface quality of the work

piece. Higher friction between tool and work piece in dry machining can increase the

temperature in cutting region. In milling cutting, tool does not cut continuously and the using

of cutting fluids increase thermal shock effect. Hence, dry machining is better suited for

milling operations. In drilling, especially gun drilling the most important function of cutting

fluid is the chip removal and dry cutting may induce drill breakage.

1.10.2 Minimum Quantity of Lubrication (MQL):

Due to economic, ecological and technical reasons, at present it is attempting to reduce the use

of oils and cutting fluids in metal cutting. The first option is dry machining, but in many cases

this is impossible due to the nature of the work piece materials. During machining, many

nonferrous alloys, and especially aluminium, tend to be adhered to tool edges, giving rise to

complex problems like the wrong cutting of the work piece material and leading to a high tool

wear. In this case, an interesting option is the use a lubrication/coolant system based on the

injection of pressurized air with small quantities of oil. This technique is designated MQL

(Minimum Quantity of lubrication). In MQL the chip, work piece and tool holder have a low

residue of lubricant thus their cleaning is easier and cheaper as compared to flooding of cutting

fluid. The cutting region is not flooded in MQL during machining so the operation can be seen

by the operator. MQL is used as a lubricating method rather than cooling. This poor cooling

capacity limits the effectiveness of MQL in machining of difficult-to-machine materials such

as titanium and nickel based alloys due to the excessive heat generation. Several experimental

INTRODUCTION


studies have investigated for the performance of MQL in the drilling, turning, milling and

grinding processes. The most literature studies compared the performance of MQL with dry

cutting and flood application. The overall performance (cutting force, tool life, surface finish,

cutting ratio, cutting temperature and tool-chip contact length) during MQL was found to be

superior to dry and conventional wet turning of hardened steel. The problem is that the

mineral based oil is poor in biodegradability and thus it’s potential for long term pollution of

the environment and workers health. The growing demand for biodegradable materials has

opened avenue for using vegetable oils as an alternative to conventional cutting fluids.

1.11 Drawbacks of petroleum based cutting fluids:

Due to the importance of cutting fluids, significant issues have been raised in their application,

recycling and disposal. Proper selection and application can reduce manufacturing cost and

improve productivity on the other hand, manufacturing failure and wastes can be experienced

by misuse of cutting fluids. And regarding to the environmental impacts and health hazards by

cutting fluids, recycling and disposal of cutting fluid are also of great importance. Improper

disposal actions can cause severe health and environmental problems. These problems gave

provision for the introduction of mineral, vegetable and animal oils. These oils play an

important role in enhancing various aspects of machining properties, including corrosion

protection, anti-bacterial protection, lubricity, chemical stability and even emulsibility.

1.12 Vegetable based cutting fluid:

A ―Vegetable oil‖ is a triglyceride extracted from a plant. Vegetable oils that are solid at room

temperature are sometimes called vegetable fats. Vegetable oils can be classified in to various

ways depending upon the source, application etc.., oils can be edible or non-edible in nature.

Compared to mineral oils vegetable oils in general possess high flash point, high viscosity

index, high lubricity and low evaporative losses. Vegetable oils are extracted from plants by

placing the relevant part of the plant under pressure, to squeeze the oil out. Oils (edible or non-

edible) may also be extracted from plants by dissolving parts of plants in water or another

solvent, and distilling the oil, or by infusing parts of plants in base oil. Various researchers

have proved the worth of edible vegetable oils viz., coconut oil, palm oil, soya bean oil, canola

oil to be used as eco-friendly fluid in recent past. But in present situations harnessing edible

oils for lubricants formation restricts the use due to increased demands catering the growing

population worldwide and local availability. Non-edible vegetable oils and other tree borne

INTRODUCTION


seeds can prove to be an effective alternative, although limited research has been done on

varieties like PongamiaPinnata (karanja), Jatrophacurcas (Ratanjyot) etc., prominently for

biofuel applications and needs focused attention for fulfilling the environmental friendly

lubricant need their full potential. Castor, Mahua and Neem also process certain properties

which makes them a promising candidate for such formulations. Non-edible vegetable oils are

renewable and biodegradable in nature.

1.13 Applications of vegetable oils:

Vegetable oils are used as an ingredient (or) component in many manufacture products. These

oils are particularly suitable as drying oils, and are used in making paints and other wood

treatment products. Vegetable oils are increasingly being used in the electrical industry as

insulators. As vegetable oils are not toxic to the environment, biodegradable if spilled and have

high flash and fire points. However, vegetable oils are less stable chemically, so they are

generally used in systems where they are not exposed to oxygen. Vegetable oil is being used to

produce biodegradable hydraulic fluid and lubricant.

1.13.1 Edible oils:

A liquid fat that is capable of being eaten as a food or food access, like Coconut, Olive, Soya

bean, Sunflower, Palm, Peanut, Rapeseed, Corn etc. Various countries import edible for their

food requirements. India is the biggest importer of edible oils in the world. Approximately,

16.6 million tons of edible oils consumed each year in India. Therefore, edible oil seeds usage

for lubricant needs may not be able to meet domestic requirements for ever increasing

population.

1.13.2 Non edible oils:

As an alternative non-edible vegetable oil and tree borne seeds can prove to be worthwhile.

These products from non-edible vegetable oils like Neem, castor, Mahua, rice bran, karanja,

Jatropha, and linseed oils which offer better or at least same performance as petroleum oil

based products besides being less expensive [8, 9]. Non edible vegetable oils are technically

and environmentally acceptable and easily available resource for bio lubricants.

1.14 Current Status — Non Edible Vegetable Oils:

Being a tropical country, India is rich in forest resources having a wide range of trees, which

yield a significant quantity of oilseeds. India is importing crude petroleum & petroleum

INTRODUCTION


products from Gulf countries. Indian scientists searched for an alternate to petroleum based

lubricant to preserve global environment and to withstand economic crisis. Table 1.2 shows

some Non-Edible Vegetable Oils Available in India.

Table 1. 2Vegetable oils available in India

S.No Non Edible Species

Available in India

Scientific Name Oil Content (%

of volume)

Annual Oil

Production

1 Jatropha JatrophaCurcas

L

25-35 % 15,000

Tonnes/Annum

2 Karanja MillettiaPinnata 20-25 % 55,000

Tonnes/Annum

3 Castor RicinusCommu

nis L

37.2-60.6 % 0.73 MT/

Annum

4 Mahua MadhucaIndica 35 – 40 % 100,000

Tonnes/Annum

5 Neem AzazdirachtaInd

ica

20 – 30 % 180,00

Tonnes/Annum

6 Kusum Schleicheratriju

ga Wild

(Sapindaceae)

34% 25,000

Tonnes/Annum

7 Sea mango tree Cerberamanghas 54 % -

8 Rubber Seed HeviaBrasiliensi

s

45 - 49 % 3500

Tonnes/Annum

9 Wild Apricot PrunusArmeniac

a

40-45 % 8-10 Tonnes/Ha

10 Linseed Linumusitatissi

mum, Linaceae

35-45 % 150,000

MT/Annum

11 Rice Bran Oryza sativa 16-32 % 474,000/Annum

12 Jojoba Simmondsiachin

ensis

45-55 -

13 Simarouba Simaroubaglauc

a DC

60-75% 1.1-2.2oil/Ha Yr

Summary:

In this chapter Introduction to vegetables and its effect on different machining processes were

discussed. The characteristics of good cutting fluid, disadvantages of petroleum based oils and

advantages of vegetable based oils were discussed.

LITERATURE REVIEW


Chapter-2

LITERATURE REVIEW

In any machining industry, turning and drilling are the most commonly carried operations. The

cutting fluids used cannot be same in the both the operation as the machining conditions are

different. Fig 2.1 and Fig 2.2 shows differences between Turing and Drilling Operation.

Fig 2. 1Turing Operation

(Source:Machinetools.com)

Fig 2. 2Drilling Operation (Source: mini-

lathe.com)

Tool used is single point cutting tool and

during machining the contact area between

tool and work piece is less, so heat generated

due to friction is comparatively less.

Drill bit used for machining is multi

point cutting tool and during machining

the contact area between tool and work

piece is more, so heat generated due to

friction is comparatively high.

Chips move out easily from the area of

machining

Chips cannot move out easily from the

area of machining (hole drilled). Chip

disposal is not easy.

Heat generated is absorbed fast by the

environment (air) as machining process is

open.

Heat dissipation is not as fast like

Turing as process closed.

LITERATURE REVIEW


The cutting fluid used in drilling should have:

a. Better cooling characteristics

b. Higher lubricating characteristics

c. High flash point

d. High fire point

e. High viscosity so that it should flow in to the cutting zone and absorb heat and carry chips

fast from the cutting zone along the flutes.

A review of general information regarding machining using vegetable oil-based cutting

fluids through various coolant conditions during turning, drilling, and milling process, on

various work materials like steel, Aluminium and so on is provided. An overview of the

previous work done by other researchers includes the studies conducted to investigate the

influence of various vegetable oils as cutting fluid on different work material are also

presented.

2.1 Vegetable based oils:

(S.A. Lawal, Application of vegetable oil-based metalworking fluids in machining ferrous

metals—A review, 2011) carried out a review on the applicability of vegetable oil based metal

working fluids in machining of ferrous metal. The advantages of metal working fluids and its

performances with respect to cutting force, surface finish of the work piece, tool wear, and

temperature at the cutting zone have been studied. The review focuses on the performance and

environmental impact of this vegetable oil as emulsion and straight oils for various materials

and machining conditions. (M. M. A. Khan, 2009) investigated the effects of minimum quality

lubrication (MQL) by vegetable oil based cutting fluid under turning operation of low alloy

steel AISI 9310.The results were compared with completely dry and wet machine in terms of

tool- chip interface temperature, chip formation mode, tool wear and surface roughness.

Results show that MQL provides environmental friendliness and improves the machinability

characteristics. (Vaibhav Koushik A.V, 2012) worked on metal working fluids that are widely

employed to increase the machining productivity and quality of metal cutting, but the usage

poses great threat to the ecology health of workers in industry. Therefore a need arose to

identify eco-friendly and hazard free alternatives to convention mineral oil based material

working fluid. In this review paper an effort has been undertaken to provide highlights of

LITERATURE REVIEW


vegetable oils over petroleum based oils. Many research works showed that vegetable oils have

promising scope of their emergence as metal working fluids. (J. B. Shaikh, 2014) in his work

determined the influence of lubricant on surface roughness and material removal rate (MRR)

by using CNC lathe machine with AISI D2 Steel. Taguchi method was used for determining

and optimizing operating parameters. The above experimentation results help practitioners to

compare and increase MRR, surface finish using more environmental friendly oil as lubricant.

(Lawal, 2013) studied cutting fluids which consists of simple oil applied with brushes to cool

and lubricate the machine tool. However cutting fluid formulation became more complex as

cutting operation became more severe. In this paper, attention is focused on recent research

work on the application of vegetable oil based cutting fluids in machining nonferrous metals.

The results obtained established that vegetable oil based cutting fluids are good metal working

fluid. (Babur OzcelikEmel kuram, 2013) focused on both formulation of vegetable based

cutting fluids and machining with these cutting fluids. For this purpose characterization of

chemical and physical analyses of these formulated cutting fluids are carried out. Experimental

results show that Canola based cutting fluid gives the best performance due to its higher

lubricant properties with respect to other cutting fluids with constant cutting conditions.

(Frank L. Erickson, 1993), In his invention relates to lubricant compositions and lubricant

additives and to methods for producing lubricant additives with antifriction properties that

contain vegetable oil and vegetable oil derivatives as lubricating agents. More specifically, this

invention relates to wax esters of vegetable oil fatty acids, sulfurized vegetable oil

triglycerides, sulfurized vegetable oil wax esters, vegetable oil triglycerides, phosphite adducts

of vegetable oil triglycerides, and phosphite adducts of vegetable oil wax esters as lubricant

additives in various combinations, and from various vegetable oil sources.

(Jones, 23rd December 1986) his invention relates to plant or vegetable oil-based drilling fluid

compositions which are non-polluting and non-toxic, and which provide improved lubricating

properties and stability for use under widely-varying load and pressure drilling conditions. The

compositions are primarily based on plant or vegetable oils comprising essentially extended

long-chain carboxylic acids having minimal double and triple bonds of the 12 to 24 carbon

atom series. The oils are selected from the group consisting of peanut oil, rapeseed oil, soybean

oil, sunflower oil, corn oil, cottonseed oil, rice bran oil, safflower oil, castor bean oil, palm oil

and mixtures thereof. Suitable antioxidants and emulsifiers as well as desired viscosifiers and

LITERATURE REVIEW


fillers are included in the compositions which are adapted to addition to water and/or brine for

desired rheological properties for drilling fluid uses. (Sune Andlid, 2nd December

1980.)worked on Metal working emulsion of the type oil-in-water, with good stability and

unlimited dilatability, intended for use at deforming metal working, mainly machining by

detachment of cuttings, but also suitable for deep drawing and rolling. The emulsion is based

on triglyceride oils and components of these. The emulsifying system consists of fatty acid

mono glycerides and alkali soaps of fatty acids. The cooling and lubricating properties are

further increased by the addition of fatty acids and an alkanol amine or fatty amine. (Edward

A. SUGG, 26th September 2013), An oil composition including at least three vegetable oils,

each vegetable oil being distinct from the other and each having a smoke point above

200F,wherein the combined volume of the at least three vegetable oils is at least about 25% of

the total volume of the oil composition. A method of removing or preventing carbon fouling on

a mechanical component of a device, comprising depositing a vegetable oil composition on the

mechanical component of the device, wherein the vegetable oil composition comprises at least

one vegetable oil having a smoke point above 200F, wherein the at least one vegetable oil is

present in an amount of at least about 25% by volume of the total volume of the oil

composition and wherein operation of the device deposits carbon on the mechanical

component.

2.2 Edible oils:

(M. Venkata Ramana) discussed about specific study and application of bio-asserted cutting

fluid such as palm oil and turning of Titanium alloy (Ti-6Al-4V) and application of solid

lubricant mixture like boric acid in palm oil on turning of Ti-6Al-4V alloy is studied. The work

involves experimental investigations of the performance of three cutting conditions such as

dry, palm oil, mixture of palm oil and boric acid lubricant in terms of surface roughness. The

results showed considerable improvement in the machining performance using palm oil and

blend of palm oil with boric acid compared with dry machining. (SharafadeenK.Kolawole,

2013.) evaluated performances of palm oil and ground nut oil when compared with that of

mineral oil based cutting fluid during machining operation of mild steel. Palm oil gave the

overall highest thickness of 0.27mm probably due to its better lubricating property. Based on

these results, ground nut oil and palm oil are being recommended as variable alternative

lubricants to the mineral oil during machining of mild steel. (M.A.Fairuz, 2015)Investigated

LITERATURE REVIEW


Chip Formation and Tool Wear in Drilling Process Using Various Types of Vegetable-Oil

Based Lubricants. This research paper represents the machinability of using several possible

vegetable oils as cutting fluid in term of chip formation and tool wear during drilling operation

on stainless steel, AISI 316. The performance of the vegetable oils; palm, sesame, olive and

coconut oils were compared under minimum quantity lubrication (MQL) technique. The result

reported that the coconut oil indicates the best machinability in terms of highest and uniform

chip thickness and least wear on the drill bit under same condition with others. These

performances are followed by palm, olive and sesame oil. In additional, the viscosity

measurement indicates that coconut oil has the lowest value which can possesses better fluidity

and faster cooling capacity than other oils. Overall, coconut oil is recommended as viable

alternative lubricants during drilling of stainless steel. (Babur OzcelikEmel kuram, 2013)

studied the Effects of vegetable-based cutting fluids on the wear in drilling. This work focused

on both formulation of vegetable-based cutting fluids (VBCFs) and machining with vegetable-

based cutting fluids. Performances of three VBCFs developed from crude sunflower oil,

refined sunflower oil, refined canola oil and commercial semi-synthetic cutting fluid are

compared in terms of tool wear, thrust force and surface roughness during drilling of AISI 304

austenitic stainless steel with HSSE tool. Experimental results show that canola based cutting

fluid gives the best performance due to its higher lubricant properties with respect to other

cutting fluids at the constant cutting conditions (spindle speed of 750 rpm and feed rate of 0.1

mm/rev). (E. Kuram, 2010), in their work studied the Effects of the Cutting Fluid Types and

Cutting parameters on Surface Roughness and Thrust Force. Three different vegetable-based

cutting fluids developed from raw and refined sunflower oil and two commercial types

(vegetable and mineral based cutting oils), were used as cutting fluid ,and thrust force and

surface roughness during drilling of AISI 304 austenitic stainless steel with HSSE tool was

determined. The results showed Lower thrust force values were obtained with SCF-I and the

least thrust force was achieved at spindle speed of 720 rpm. SCF-I generated the highest

reduction in thrust force when AISI 304 stainless steel drilled at a feed rate of 0.12 mm/rev and

a drilling depth of 21 mm. When AISI 304 stainless steel was drilled, CVCF had low thrust

force and the least thrust force was achieved at feed rate of 0.08 mm/rev. The least surface

roughness was achieved at spindle speed of 720 rpm using CVCF. SCF-I was the most

effective in reducing surface roughness as spindle speed increased. SCF-II had the smallest

LITERATURE REVIEW


surface roughness at feed rates lower than 0.12 mm/rev. The least surface roughness was

achieved at feed rate of 0.08 mm/rev using SCF-II. (Odusote, 2013) studied the performances

of palm oil and groundnut oil, obtained results were compared with that of mineral oil-based

cutting fluid during drilling operation of mild steel. Temperature of the work piece as well as

their chip formation rates using these vegetable oils as cutting fluids under different cutting

speed (rev/min), feed rate (mm/rev) and depth of cut (mm) were compared with that of mineral

oil and dry machining. The temperature of the work piece when groundnut oil was used as the

cutting fluid was very close to that of the conventional oil, which was the lowest. Palm oil gave

the overall highest chip thickness of 0.27 mm probably due to its better lubricating property.

This was followed by that of the groundnut oil and the conventional oil as compared with dry

machining of 0.17 mm thickness. Vitamin-C- rich-lemon fruit extract was used as an

antioxidant to improve the oxidative stability of the vegetable oils. Viscosities of the various

fluids were also analysed, and lowest average viscosity value of 28.0 Poise was obtained using

groundnut oil. This shows that groundnut oil possesses better fluidity and faster cooling

capacity than other oil samples. Samples lubricated with mineral-oil based fluid show fine

microstructures, similar to what obtained using groundnut oil based cutting fluid. Fine surface

morphology indicates improved surface roughness compared to using other cutting fluids.

Based on these results, groundnut oil and palm oil are being recommended as viable alternative

lubricants to the mineral oil during machining of mild steel.

2.3 Non-Edible oils:

(Suhane, 2014)in their research showed that lubricants provide smooth operation between

movable parts of all machines. It maintains the reliability of machine functions and reduces the

risk of failures. Vegetable bio lubricants are non-toxic, degradable, and renewable also possess

good lubricating properties. In his work, he reviewed papers on edible oils as cutting fluids.

While in few papers non-edible oils such as castor, karanja, mahua were used and proved to

have a great potential as lubricant for some of the machining operations.

2.4 Drilling Operation:

(A.R. Ismail, 2015) carried out a study on drilling operation where oil based drilling fluid offer

less torque and drag. The work concluded that water based drilling fluid are cheaper and

environmental friendly compared to oil based and synthetic based drilling fluids. Addition of

lubricants helps in improving the rheological properties of the water based drilling fluid.

LITERATURE REVIEW


(Abdul Razak Ismail, 2014) in their research showed that addition of lubricants helps in

improving the rheological properties of the water based drilling fluid. EBL lubricant seemed

give more improvements to the water based drilling fluid in term of yield point, gel strength

and filtrate loss compared to EME salt. Coefficient of friction (CoF) for both lubricants in the

water based drilling fluid had been reduced at an optimum concentration value of 1 – 2%.

2.5 Literature review on Additives used for different cutting fluids:

(Yasuo Fukutani, 2001) studied about water-soluble cutting fluid which is characterized by

excellent cooling and lubricating properties and does not exert a harmful influence on the

environment. A solution containing hydrogen carbonate ion, bromide ion, carbonic acid ion,

and, if necessary, fluoride ion, and being adjusted to a pH of 7.0 to 11.5 can be used as a

substitute for cutting oil. A water-soluble cutting fluid further including additives such as rust-

preventive agents and the like can be also used as a substitute for conventional cutting oil.

2.6 Aim, Objectives and Methodology:

From the above literature survey it is concluded that there is no work done using the Neem Oil

and Karanja Oil on Drilling Operation and also there is no drilling work done on Mild Steel

Specimens. That is the main reason for us to choose these two oils as Cutting Fluids in Drilling

Operation on Mild Steel Specimen.

Aim: To investigate various cutting parameters using Eco-friendly Non Edible vegetable oil as

cutting fluid and to study its influence on microstructure and wear properties during drilling

operation of Mild Steel.

Objectives:

In recognition the importance of cutting fluid in machining, this project tried to achieve the

following objectives:

a. To study the operating characteristics of non-edible oil as metal cutting fluid during drilling

operation for mild steel.

b. To conduct experiment for various machining parameters like surface finish, chip-length,

pitch length, chip thickness, and cutting force, by using non edible oil as cutting fluid.

c. To compare the results obtained from non-edible oil, with petroleum based oil and dry

running conditions during drilling operation.

LITERATURE REVIEW


Methodology:

Objective-1:

To study the operating characteristics of non-edible oil as metal cutting fluid during drilling

operation for mild steel.

Methodology:

The detailed literature survey are carried out on

• Understanding the use of different types of cutting fluids for different Machining

operations

• Various Vegetable based oils used as a cutting fluid during various machining

operations like turning, milling, grinding.

• Effect of Vegetable based oils on the cutting parameters in Drilling operation.

Objective-2:

To conduct experiment for various machining parameters like surface finish, chip-length, pitch

length, chip thickness, and cutting force, by using non edible oil as cutting fluid.

Methodology:

• Various Vegetable based oils used as a cutting fluid during various machining

operations like turning, milling, grinding.

• Effect of Vegetable based oils on the cutting parameters in Drilling operation.

Objective-3:

To compare the results obtained from non-edible oil, with petroleum based oil and dry running

conditions during drilling operation.

Methodology:

• Cutting force, viscosity, cutting temperature, flash and fire points and surface

roughness of work pieces used with different cutting fluids were discussed.

• The micro structure and hardness on the surface and its role in determining good

cutting fluids are studied in details.

• Wear characteristics of work pieces obtained after machining with Eco-friendly

vegetable oil and petroleum based cutting fluid.

LITERATURE REVIEW


Summary:

This chapter summarizes different characteristics of cutting fluids required specifically for

drilling operation and also presents a brief review about recent work carried out using various

vegetable based oils on various materials for different machining operations. Many papers

discussed the effect of these cutting fluids on machining efficiency like surface finish, cutting

force and so on.

EXPERIMENTAL DETAILS


Chapter-3


3.1 Selection of Bio-Oils:

Cutting fluids are used to reduce the negative effects of the heat and friction on both tool and

work piece. The cutting fluids produce three positive effects in the process heat removal,

lubrication on the chip-tool interface and chip removal. However, the advantages caused by the

cutting fluids have been questioned lately, due to several negative effects they have caused in

the environment and worker health. When inappropriately discharged, cutting fluids may

damage soil and water resources, causing serious environmental impacts. On the shop floor,

the machine operators may be affected by the negative effects of cutting fluids, such as skin

and respiratory problems. For these cases alternative solutions are developed to avoid

environment and health.

The use of vegetable oils allows high performance in machining combined with good

environment compatibility could be achieved. Compared to mineral oil, vegetable oil can even

enhance the cutting performance, extend tool life and improve the surface finish. Although,

they have many environmental benefits, vegetable oils are more susceptible to degradation by

oxidation or hydrolytic reactions.

A vegetable oil is a triglyceride extracted from a plant. Vegetables oils are classified in

two types. They are edible and non-edible oils. Vegetables oils which are used for cooking

purposes are called edible oils such as coconut oil, palm oil, palm kernel oil etc., are called as

non-edible oils. Non-edible vegetable oils are technically and environmentally acceptable and

easily available resource for bio-lubricants. The non-edible oils have large scope to utilize

them as metal working fluids. This makes to select non-edible oils such as Neem and Karanja

as cutting fluids.

3.1.1 Neem oil:

Neem oil is a vegetable oil pressed from the fruits and seeds of the Neem (Azadirachtaindica),

an evergreen tree which is endemic to the Indian subcontinent and has been introduced to

https://en.wikipedia.org/wiki/Vegetable_oil

https://en.wikipedia.org/wiki/Azadirachta_indica

https://en.wikipedia.org/wiki/Evergreen

https://en.wikipedia.org/wiki/Endemic_%28ecology%29

https://en.wikipedia.org/wiki/Indian_subcontinent



many other areas in the tropics. It is the most important of the commercially available products

of Neem for organic farming and medicines. Table 3.1 shows composition of Neem oil.

Table 3. 1Composition of Neem oil

Average composition of neem oil fatty acids

Common Name Acid Name Composition range

Omega-6 Linoleic acid 6-16%

Omega-9 Oleic acid 25-54%

Palmitic acid Hexadecanoic acid 16-33%

Stearic acid Octadecanoic acid 9-24%

Omega-3 Alpha-linolenic acid %

Palmitoleic acid 9-Hexadecenoic acid %

3.1.2 Karanja oil:

Karanja oil is derived from the seeds of the Millettiapinnata tree, which is native to tropical

and temperate Asia. Millettiapinnata, also known as Pongamiapinnata or Pongamiaglabra, is

common throughout Asia. Table 3.2 Shows the compostition of Karanja oil.

Table 3. 2Composition of Karanja oil

Fatty Acids Nomenclature Percentage

Stearic

C18:0

2.4%-8.9%

Oleic

C18:1

44.5% – 71.3%

Linoleic

C18:2

10.8% -18.3%

Linolenic

C18:3

2.6%

Arachidic

C20:0

2.2% – 4.7%

Eicosenoic

C20:1

9.5% – 12.4%

Behenic

C22:0

4.2% – 5.3%

Lignoceric

C24:0 1.1% – 3.5%

https://en.wikipedia.org/wiki/Fatty_acid

https://en.wikipedia.org/wiki/Omega-6_fatty_acid

https://en.wikipedia.org/wiki/Linoleic_acid


https://en.wikipedia.org/wiki/Oleic_acid

https://en.wikipedia.org/wiki/Palmitic_acid

https://en.wikipedia.org/wiki/Stearic_acid


https://en.wikipedia.org/wiki/Alpha-linolenic_acid

https://en.wikipedia.org/wiki/Palmitoleic_acid

https://en.wikipedia.org/wiki/Millettia_pinnata

https://en.wikipedia.org/wiki/Asia

https://en.wikipedia.org/wiki/Pongamia

https://en.wikipedia.org/wiki/Stearic_acid

https://en.wikipedia.org/wiki/Oleic_acid

https://en.wikipedia.org/wiki/Linoleic_acid

https://en.wikipedia.org/wiki/%CE%91-Linolenic_acid

https://en.wikipedia.org/wiki/Arachidic_acid

https://en.wikipedia.org/wiki/Eicosenoic_acid

https://en.wikipedia.org/wiki/Behenic_acid

https://en.wikipedia.org/wiki/Lignoceric_acid



3.2 Physical Properties:

The Table3.3 shows the physical properties of cutting fluids used in this work.

Table 3. 3Physical properties of cutting fluids used in this work

S.No Type of cutting

fluid

Flash point

(°C)

Fire point

(°C)

Kinematic

viscosity (m²/s)

Dynamic

Viscosity (N-

s/m²)

1) Neem 248 285 4.343*10ˉ⁵ 0.0345

2) Karanja 220 245 4.107*10ˉ⁵ 0.0266

3) 50%neem

50%karanja

226 260 2.536*10ˉ⁵ 0.01648

4) 33.3%neem

66.6%karanja

228 256 2.078*10ˉ⁵ 0.0135

5) 66.6%neem

33.3%karanja

228 264 1.734*10ˉ⁵ 0.011271

6) Petroleum based

oil

210 220 3.43×10ˉ5

0.02172

The cutting fluid should possess high flash and fire points, as it should not catch fire at high

temperatures. From the above table, Neem oil has got high flash and fire points, but viscosity

also matters. The viscosity of a lubricant is closely related to its ability to reduce friction.

Generally, the least viscous lubricant which still forces the two moving surfaces apart is

desired. If the lubricant is too viscous, it will require a large amount of energy to move (as in

honey); if it is too thin, the surfaces will come in contact and friction will increase. From the

above table the blend of Neem and Karanja oil (50% Neem-50% Karanja) has moderate

viscosity. So, this blend is considered as best cutting fluid.

https://en.wikipedia.org/wiki/Lubricant

https://en.wikipedia.org/wiki/Friction

https://en.wikipedia.org/wiki/Lubricant

https://en.wikipedia.org/wiki/Honey



3.3 Equipment used:

3.3.1 Cleveland open cup tester:

Fig 3. 1Cleveland open cup tester

The Cleveland open-cup method as shown in Fig 3.1 is one of three main methods in chemistry

for determining the flash point of the oils using a Cleveland open-cup apparatus, also known as

a Cleveland open-cup tester. Using this test the flash and fire points of different cutting fluids

were found out.

3.3.2 Saybolt viscometer:

Fig 3. 2Saybolt viscometer

Saybolt viscometer as shown in Fig 3.2 is a device used to measure the viscosity of a fluid. The

Saybolt viscometer control the heat of the fluid and the viscosity is the time is takes the fluid to

fill a 60cc container.

https://en.wikipedia.org/wiki/Flash_point



3.3.3 CNC Drilling machine:

Computer Numerical control (CNC) is the automation of machine tools that are operated by

precisely programmed commands encoded on a storage medium, as opposed to controlled

manually by hand wheels or levers, or mechanically automated by cams alone as shown in Fig

3.3.

Fig 3. 3 CNC Machine

3.3.4 Lathe Machine:

A lathe is a machine tool as shown in Fig 3.4 that rotates the work piece on its axis to perform

various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning,

with tools that are applied to the work piece to create an object with symmetry about an axis of

rotation.

Fig 3. 4Lathe Machine

https://en.wikipedia.org/wiki/Automation

https://en.wikipedia.org/wiki/Machine_tool

https://en.wikipedia.org/wiki/Machine_tool

https://en.wikipedia.org/wiki/Axis_of_rotation

https://en.wikipedia.org/wiki/Cutting

https://en.wikipedia.org/wiki/Sanding

https://en.wikipedia.org/wiki/Knurling

https://en.wikipedia.org/wiki/Drilling

https://en.wikipedia.org/wiki/Deformation_%28engineering%29

https://en.wikipedia.org/wiki/Facing_%28machining%29

https://en.wikipedia.org/wiki/Turning

https://en.wikipedia.org/wiki/Rotational_symmetry





3.3.5 IR Thermometer:

Fig 3. 5 IR Thermometer (Source: www.gaussmeter.info)

An infrared thermometer as shown in Fig 3.5 is a thermometer which infers temperature from a

portion of the thermal radiation emitted by the object being measured. They are sometimes

called laser thermometers if a laser is used to help aim the thermometer. Here IR thermometer

is used to measure the tool temperature and work piece temperature during machining.

3.3.6 Profile Projector:

Fig 3. 6 Profile Projector

A profile projector as shown in Fig 3.6 is also referred to as an optical comparator, or even

known as a shadowgraph, a profile projector is an l instrument utilized for measuring. The

projector magnifies the profile of the specimen, and show this on the built in projection screen.

From this screen there is usually a grid that could be rotated 360 degrees therefore the X-Y

axis of the screen could be aligned correctly using a straight edge of the chip to analyze or

measure.

https://en.wikipedia.org/wiki/Thermometer

https://en.wikipedia.org/wiki/Thermal_radiation

https://en.wikipedia.org/wiki/Laser



3.3.7 Surface finish tester:

Roughness can be measured by manual comparison against a "surface roughness comparator",

Shown in Fig 3.7 is a sample of known surface roughness, but more generally a Surface profile

measurement is made with a profilometer that will be in contact with the surface to be

measured (typically a diamond stylus).

Fig 3. 7 Surface roughness tester

3.3.8 Hardness testing machine:

Hardness is the property of a material that enables it to resist plastic deformation, usually by

penetration. However, the term hardness may also refer to resistance to bending, scratching,

abrasion or cutting. The Rockwell hardness test method as shown in Fig 3.8 consists of

indenting the test material with a diamond cone or hardened steel ball indenter. The indenter is

forced into the test material under a preliminary minor load. When equilibrium has been

reached, an indicating device, which follows the movements of the indenter and so responds to

changes in depth of penetration of the indenter, is set to a datum position. While the

preliminary minor load is still applied an additional major load is applied with resulting

increase in penetration. When equilibrium has again been reach, the additional major load is

removed but the preliminary minor load is still maintained. Removal of the additional major

load allows a partial recovery, so reducing the depth of penetration. The permanent increase in

depth of penetration, resulting from the application and removal of the additional major load is

used to calculate the Rockwell hardness number. Rockwell hardness tester is used as the work

piece material is mild steel and it soft and load required for indentation is very less compared

with cast iron.

https://en.wikipedia.org/wiki/Surface_profile_measurement

https://en.wikipedia.org/wiki/Surface_profile_measurement



Fig 3. 8 Hardness testing Machine

3.3.9 Dynamometer Meter:

The Drill tool dynamometer ass shown in Fig 3.9 is a cutting force measurement transducer

specially designed to measure the cutting forces on the coming on the tool tip on the drilling

machine. The dynamometer has two directional force measurements such as TORQUE and

THRUST. The sensor is mounted on the machine table of the drilling machine. Self-centering

vice is fixed on the sensor. The job held with the vice and the job is drilled with a drill bit. The

sensor mounts the torque and thrust force generated between the job and the tool bit.

Fig 3. 9 Drill tool Dynamometer

3.3.10 Optical Microscope:

The Optical Microscope often referred to as light microscope is a type of microscope which

uses visible light and a system of lenses to magnify images of small samples which is shown in



Fig 3.10 . The images from an optical microscope can be captured by normal light sensitive

cameras to generate a micro graph. Here optical microscope is used to find out the micro

structure of the mild steel specimen.

Fig 3. 10 Optical Microscope

3.4 Experimental procedure and conditions:

The properties of cutting fluids depend on specific heat, adhesiveness and dynamic viscosity.

For the cutting fluid selected i.e., Karanja, Neem, blends of Neem and Karanja with different

percentages, petroleum based oils (SAE 20W40), all these physical properties have been

determined and compared.

The experimental analysis initially started in a medium duty lathe and the work piece is

firmly held in a 3-jaw chuck at cutting speed of 775 rpm. AISI 1014 mild steel having diameter

of 25mm with 75mm length was taken. Before drilling operation, the work piece was faced and

turned for finishing in lathe. A drill bit of HSS with 10% cobalt with diameter of 13mm is used

for drilling, but before this centering is done for all the work pieces using center drill. The

depth of the hole is 30mm with constant speed and feed. The drilling operation is carried out

on a CNC drilling machine at 800 rpm at constant feed 10 mm/rev using Karanja, Neem,

blends of Neem and Karanja with different percentages, petroleum based oils as cutting fluids

and also in dry condition. The method of MQL (Minimum quantity lubrication) is used for

supplying the cutting fluid. While machining a drilling tool dynamometer is used in order to

find out the cutting force required for the drilling of mild steel using different cutting fluids.

The tool temperature and specimen temperature is determined using IR thermometer by

focusing the laser on to the specimen and tool. The chips formed are collected and taken for

checking parameters. The physical parameters of the chips are found using profile projector.

The roughness of the machined surface is determined using surface roughness tester. The



specimens are tested for hardness using Rockwell hardness tester to analyze heat transferred to

the specimen during machining. The results for the above experimental analysis are discussed

in next chapter.

Summary:

This chapter gives details of Cutting Fluids used, Work piece material, Machine Tools used

and equipment used for finding physical properties of Cutting Fluids.

RESULTS AND DISCUSSION


Chapter-4


4.1 Physical Properties of Cutting fluids:

4.1.1 Flash Point and Fire Point:

The flash point is the lowest temperature at which vapors of a fluid ignite. Flash point is used

to characterize the fire hazards of liquids. Every liquid has a vapor pressure, which is a

function of that liquid’s temperature. As the temperature increases, the vapor pressure

increases. As the vapor pressure increases, the concentration of vapor in the air increases. A

certain concentration of vapor in the air is necessary to sustain combustion, and that

concentration is different for each liquid. At flash point, a substance will ignite briefly; vapor

might not be produced at a rate to sustain the fire. Table 4.1, shows the measured flash and fire

point of different cutting fluids used in the present study. The flash point of blend of 50%Neem

and 50%Karanja is 2560C, which is very high compared to other cutting fluids. Hence blend of

50%Neem and 50%Karanja is best in resisting the flame.

The fire point is the temperature at which the vapor produced by that given fluid will

continue to burn for at least 5 seconds after ignition by an open flame. Higher the fire point

greater will be the resistance to ignite. Hence good cutting fluid should have higher fire point,

so that it should not catch fire at drilling temperature. The blend of 50%Neem and 50%Karanja

has highest fire point of 290°C is good at resisting the flame, followed by blend of Neem and

with 285°c. The flash and fire points of are calculated by using Cleveland’s apparatus.

Table 4. 1Flash Points and Fire points of different cutting fluids

Sl.No Type of cutting fluid Flash

point (°C)

Fire point

(°C)

1) Neem 248 285

2) Karanja 220 245

3) 50%Neem50%Karanja 256 290

4) 33.3%Neem66.6%Karanja 228 256

5) 66.6%Neem33.3%Karanja 228 264



6) SAE 20W40 210 215

4.1.2 Viscosity:

The viscosity of a fluid is a measure of its resistance to gradual deformation by shear stress or

tensile stress or it refers to resistance to flow. A good cutting fluid should have optimum

viscosity i.e. if it is high then oils does not carry away heat and chip from machining zone and

it will stick the chip in the machining area effecting machining efficiency. If it is low then it

will just pass away from machining zone without lubricating the tool and work piece. Viscosity

of selected oils is measured by using saybolt viscometer and values obtained are tabulated in

table 4.2.Since viscosity related to motion of oils is important, dynamic viscosity plays an

important role, from the table below is it seen that Neem oil has highest value of 0.0345 N-

s/m²,least is 0.011271 N-s/m² for 66.6%Neem 33.3%Karanja and optimum is for 50%Neem

50%Karanja with 0.01648 N-s/m². This indicates that the blend of 50%Neem 50%Karanja has

both cooling and lubricating property.

Table 4. 2 Viscosity of different cutting fluids

Sl.

No

Type of cutting fluid Kinematic

viscosity (m²/s)

Dynamic Viscosity

(N-s/m²)

1) Neem 4.343×10ˉ5

0.0345

2) Karanja 4.107×10ˉ5 0.0266

3) 50%Neem

50%Karanja

2.536×10ˉ5 0.01648

4) 33.3%Neem

66.6%Karanja

2.078×10ˉ5 0.0135

5) 66.6%Neem

33.3%Karanja

1.734×10ˉ5 0.011271

6) SAE 20W40 3.43×10ˉ5 0.02172

4.1.3 Specific Heat:

The specific heat is the amount of heat per unit mass required to raise the temperature by one

degree Celsius. A good cutting fluid should have high specific heat, so that it can absorb max

heat from the machining zone to rise its temperature instead of allowing heat to transfer the

heat to tool and work piece. Table 4.3, gives measured values of Specific Heat for different



cutting fluids used. From the table it can be seen that blend of 50%Neem 50%Karanja has

highest value of 1.6991 KJ/Kg. K followed by pure Neem with value of 1.6817 KJ/Kg. K. This

shows blend is capable of absorbing higher heat from the machining zone or acts as good

coolant compared to others oils used.

Table 4. 3 Specific Heat of different cutting fluids

Sl. No

Type of cutting fluid

Specific

Heat (KJ/Kg.

K)

1) Neem 1.6817

2) Karanja 1.6761

3) 50%Neem50%Karanja 1.6991

4) 33.3%Neem66.6%Karanja 1.6703

5) 66.6%Neem33.3%Karanja 1.6789

6) SAE 20W40 1.97

4.1.4 Adhesiveness:

This property of cutting fluid refers to ability of fluid to stick to the surface of work and tool

during machining and maintain a later separating both elements, so that friction is less.

Adhesiveness should not be too high as the fluid will stick to surface along with chips formed.

This reduces the life of the tool and machining efficiency. If it is too low then the fluid cannot

separate the elements during machining resulting in higher friction and reduction to tool life. A

good cutting fluid should have optimum or moderate value of Adhesiveness, so that both the

above problems can be overcome. Table 4.4 gives the Adhesiveness measured for different

cutting fluids. Method used for this is as shown in the Fig 4.1. Neem has highest Adhesiveness

with value of 687 g/m2, least is 257 g/m

2 for blend of 33.3%Neem 66.6%Karanja and the

optimum is for blend of 50%Neem 50%Karanja with the value of 359 g/m2. This shows that

50%Neem 50%Karanja is best blend as it separates the machining elements and carries away

the heat.



(a) (b)

Fig 4. 1(a) Method used (b) equation used to measure the Adhesiveness of cutting fluid

Table 4. 4Adhesiveness of different cutting fluids

Sl.

No

Type of cutting fluid Adhesiveness(g/m2)

1) Neem 687

2) Karanja 412

3) 50%Neem50%Karanja 359

4) 33.3%Neem66.6%Karanja 257

5) 66.6%Neem33.3%Karanja 367

6) SAE 20W40 319

4.2 Study of chips:

Neem Karanja



Dry Petroleum Based

50%Neem 50%Karanja 33.3%Neem 66.6%Karanja

66.6%Neem 33.3%Karanja

Fig 4. 2 Chips formed during drilling operation on Mild steel with different cutting fluids

During Machining, chip formation usually depends on type of metal being machined i.e.

weather ductile or brittle and temperature at the machining zone. This temperature is due to

friction that exists between drill bit and the work piece. Chip may break due to chattering of

work piece and due to overheating of work surface during the cutting process. The chatter in

the material is avoided by taking larger diameter wok piece heat compared to other oils used

hence acts as good coolant by absorbing heat ,but due less dynamic viscosity and adhesively,

the petroleum based oil(SAE 20W40) does not lubricate hence friction is more as seen in work

piece temperature. Compared to all the oils, it is observed that for blend of 50% Neem and

50%Karanja longer length continuous chips of 33mm are formed indicating that temperature at

machining zone is less as shown in the figure 4.2. This can also be observed by the color of the

chip, which is not dark like obtained for other cutting fluids. The results show that blends of

50% Neem and 50%Karanja has good lubricating and cooling property.

In dry cutting machining, the value of pitch is smaller amount and pitch height is too

large, due to less control of the heat generated during the process. The heat needs to be

transferred through air and due to rotation; a heat zone is generated around the material

surface. This became a too difficult in transferring the heat from the material to surrounding.

With the use of petroleum based cutting fluids, there was increase in the value of pitch with

reduction in pitch height. An improvement in surface finish was observed with this process.



With the use of Non-edible oils, there was some stickiness between the tool/chip interface

making still increase in pitch value and reduction in pitch height making surface much

smoother as shown in Figure 3. Increase in the pitch value and decrease in the pitch height

showed that there was some improvement in the surface finish with work piece thickness.

for the study. Due to excessive heat produced during the machining, surface of work piece

material gets converted from ductile to brittle and the chip becomes discontinuous. This

discontinues chips were observed for dry condition and when Karanja is used as cutting fluid.

With petroleum based oil helped in reducing the heat but to a smaller extent. SAE 20W40 has

better specific

Table 4. 5Details of chips formed during drilling operation on Mild steel with different cutting

fluids

Sl

.No

Type of

cutting fluid

Length

(mm)

Thickness

(mm)

Coil

Diameter

(mm)

Pitch length

(mm)

Depth

(mm)

1) Neem 24.5 0.23 5.76 3.84 1.72

2) Karanja 25.7 0.185 4.18 1.11 0.87

3) 50%Neem

50%Karanja

33 0.23 5.1 2.36 1.475

4) 33.3%Neem

66.6%Karanja

20.5 0.22 5.08 5.34 1.865

5) 66.6%Neem

33.3%Karanja

30.7 0.23 3.93 2.11 0.915

6) SAE 20W40 23.9 0.25 6.4 5.13 1.73

7) Dry condition 9.1 0.21 4.45 2.66 1.86

From Fig.4.2 and Table 4.5 it is observed that continuous chips are produced from the

lubrication of blend of 50% Neem& 50% Karanja. The chips from this blend are more uniform

than others that indicate better cutting mechanisms. The greatest measurement of chip

thickness is recorded when using Neem, blend of 50% Neem& 50% Karanja and blend of

66.6% Neem& 33.3% Karanja. These cutting fluids have higher oiliness that capable to reduce

friction during drilling and it enables to achieve better condition of material removal.



4.3 Surface roughness of machined surface:

Surface finish of machined part depends on temperature at machining zone, if the temperature

is high the work surface will become brittle and the force required to cut the metal will be high

leading very rough surface. Table 4.6 shows Surface roughness measured with cutting fluid

and at dry cutting condition. In dry cutting condition, the chips were discontinuous due to the

friction in the tool and work interface. As the heat generated is high, the surface near the drill

bit becomes brittle and due high cutting force, machined is very rough with highest value of

4.157 µm .During the use of non-edible oil we found that longer chips can be achieved due to

the reduction. For Neem and blend of 50% Neem and 50% Karanja, the surface roughness

measured 1.279 µm and1.16 µm which is very less compared to other oils. This is due very

low temperature at the machining zone and work surface will be ductile in nature leading to

lesser cutting force and smooth removal of metal. In case of SAE 20W40 oil as cutting fluid

the surface roughness measured is 3.5 µm, which is due to high friction between the drill bit

and work piece.

Table 4. 6 Surface Roughness measured on machined surface for different cutting fluids and at

dry condition.

Sl. No Type of cutting

fluid

Surface Roughness

(µm)

1) Neem 1.279

2) Karanja 2.689

3) 50%Neem

50%Karanja

1.16

4) 33.3%Neem

66.6%Karanja

1.332

5) 66.6%Neem

33.3%Karanja

1.593

6) SAE 20W40 3.5

7) Dry condition 4.157



Fig 4. 3Surface Roughness of the machined surface

Fig 4. 4 Graph showing surface roughness measured on work piece with different cutting fluids

and at dry condition

4.4 Colour of the chips:

The colour of the chip is frequently noted as the measure of the temperature obtaining at the

tool point. A blue temper colour on the surface of a chip formed in dry cutting is taken to mean

that the tool point is hotter than when an uncoloured silvery chip is obtained when cutting with

a fluid. The best uncoloured silvery chip is formed when Neem oil is used as cutting fluid. For

dry condition the chips are completely burnt i.e. dark colour indicating that maximum heat is

transferred to work piece during machining.

Neem Karanja/Honge

Dry SAE 20W40

50%Neem

50%Karanja

33.3%Neem

66.6%Karanja

66.6%Neem ,33.3%Karanja



Neem Honge/Karanja

Dry condition SAE 20W40

50%Neem 50%Karanja 33.3%Neem 66.6%Karanja

66.6%Neem 33.3%Karanja

Fig 4. 5 Chips formed with different colour with application of different cutting fluid and at dry

condition

4.5 Cutting Force:

To know the performance of cutting fluid during drilling operation, it is essential to measure

the cutting force. Cutting force helps in analysing

a. Effect of speed and feed during the cutting action,

b. The effect of mechanical properties of work material

c. Force excreted on the drilling machine parts

In the present work cutting speed, feed, and work piece are kept constant and different types /

blends of cutting fluid are been used. So to know the efficiency of cutting fluid used Cutting



force is considered as one of the measure. With respect to work piece, cutting force is the

measure of resistance offered by the work piece during machining process. Smoother the drill

bit enters the work piece, lesser will be the cutting force. Therefore a good cutting fluid should

reduce the cutting force during the machining operation resulting in lesser mechanical stress in

the work piece. Table 4.7 below shows the cutting force measured during drilling of mild steel

at constant speed and feed using Drill tool dynamometer.

During machining process, cutting force depends on the friction between the tool and

work piece. More cutting force accumulates more heat in the work material and makes it soft

for further processing. This may adversely affect the quality of the material in terms of

dimensional accuracy and surface finish. A proper mechanism needs to be included in the

process to control the heat generation in the heat zone during metal removal. Table 4 shows the

cutting force for measured with different cutting fluid and at dry cutting condition. It is being

observed that during dry machining, the cutting force was increased due to excess heat

generated by the friction. During petroleum based (SAE20W40) machining it is observed that

the cutting forces were gradually reduced due to the interface of petroleum based lubricant in

between tool and work piece and in this process the petroleum based oil acts as coolant but not

as lubricant. There was further decrease in cutting force with the use of non-edible oils. For

Neem as cutting fluid, the cutting force is 169.23 N, which is less compared to SAE 20W40

(petroleum based oil) and dry cutting condition. The cutting force is decreased at higher rate

with the use of 50%Neem 50%Karanja, because of its high viscosity and Adhesiveness

between work piece and tool and this nature of the oil helped in reducing the heat generated at

the tool chip interface and also helped in reducing the cutting force.

Table 4. 7 Cutting Force measured with different cutting fluid and at dry cutting condition

Sl.

No

Type of cutting fluid Cutting

Force(N)

1) Neem 169.23

2) Karanja 215.23

3) 50%Neem 50%Karanja 184.61

4) 33.3%Neem 66.6%Karanja 194.61

5) 66.6%Neem33.3%Karanja 230.76

6) SAE 20W40 261.53



7) Dry Cutting 307.69

4.6 Hardness Test:

Hardness refers to the resistance of a material to indentations and scratching. This is generally

determined by forcing an indenter on to the surface. The resultant deformation in steel is both

elastic and plastic. The hardness values of all the specimens before drilling and after drilling

operation using different cutting fluids are determined using Rockwell hardness tester and the

results are tabulated in the table 4.8.

Table 4. 8 The hardness values of all the specimens before drilling and after drilling operation

using different cutting fluids

S.No Type of cutting fluid Hardness before

drilling

Hardness after

drilling

1 Neem 78 80

2 Karanja 77 80

3 50% Neem-50% Karanja 78 79.5

4 33.3%Neem- 66.6% Karanja 78 81

5 66.6% Neem-33.3% Karanja 77 80.5

6 SAE 20W40 (Petroleum

Based)

78 80

7 Dry 78 83

Heat generated during drilling operation due to friction between the work piece and drill bit is

given out to tool, chip and work piece if no cutting fluid is used. If the maximum heat is given

to work piece then the mechanical properties will be affected and if it is given to tool, then the

tool wear is observed leading to reduction in tool life. The function of good cutting fluid is to

absorb and carry away the heat generated in the machining zone. In the above table it is

observed that for dry condition the hardness value is 78 HRB before drilling and it is 83 HRB

after drilling which is very high compared to hardness value before drilling, which indicates

that the metal surface has absorbed more heat during machining due to which it has become

very brittle increasing its hardness. For petroleum based oil, Neem the hardness value is

initially 78HRB which got increased to 80 HRB very less compared to Dry condition,

indicating that maximum heat is absorbed by the cutting fluid and only small amount of heat is

given to the work piece resulting in lesser hardness value. For blend of 50% Neem and 50%



Karanja, the hardness value before drilling is 78 HRB and 79.5 after drilling which is very less

difference. This may be because of effective cooling and heat absorption capacity of blend

used. For other combination of blends, the difference in hardness values are very high

indicating that heat absorption is not as effective as blend of 50% Neem 50% Karanja.

Fig 4. 6 Hardness of specimen before and after drilling with different cutting fluids and at dry

condition

4.7 Temperature of work piece and drill bit during machining:

A good cutting fluid should absorb maximum heat from the machining zone, giving very less

heat to tool and the work piece, if not tool life will be less and the machining accuracy will be

also be affected along with varying the properties of work piece .Table 4.9 shows, Temperature

measured for tool and work piece with cutting fluid and at dry cutting condition. For dry

condition temperature of tool and work piece is 56.3°C and 68°C which is very high. This is

due to transfer of whatever heat generated to tool and work piece as no coolant is used and also

due to high friction between tool and work piece as no lubricant is used. For SAE 20W40 oil

the temperature measured for both tool and the work piece is 35.4 °C and 40.2°C, which is less

compared dry cutting but higher than non-edible oils used, this due to its lower adhesiveness

and lower dynamic viscosity. For 50%Neem, 50%Karanja blend the temperature of tool and

work piece is 36.2°C and 39.1°C very less value compared to other conditions. This is due high

specific heat, high adhesiveness and higher dynamic viscosity. Indicating that, this blend has

better cooling and good lubricating property.

74

76

78

80

82

84

HA

RD

NES

S

CUTTING FLUID

HARDNESS OF SPECIMEN BEFORE AND AFTER DRILLING

Hardness before drilling

Hardness after drilling



Table 4. 9 Temperature measured for tool and work piece with cutting fluid and at dry cutting

condition

Sl.

No

Type of

cutting fluid

Tool

Temperature

(°C)

Specimen

Temperature

(°C)

1) Neem 38.6 39.5

2) Karanja 43.1 49

3) 50%Neem

50%Karanja

36.2 39.1

4) 33.3%Neem

66.6%Karanja

43.4 41.3

5) 66.6%Neem

33.3%Karanja

42.9 44.7

6) SAE 20W40 35.4 40.2

7) Dry Cutting 56.3 68

Fig 4. 7 Graph Showing tool and specimen temperature with different cutting fluids and at dry

condition

01020304050607080

Axi

s Ti

tle

CUTTING FLUIDS

TOOL AND SPECIMEN TEMPERATURE

Tool Temperature

Specimen Temperature



4.8 Wear Studies of the Machined work piece surface:

Neem Karanja

50% Neem& 50% Karanja

33.3% Neem& 66.6%

Karanja

66.6% Neem& 33.3%

Karanja SAE 20W40

Dry

Fig 4. 8 Worn surface of machined Specimen with different cutting fluids and at dry condition



Wear refers to removal of excess material from work piece surface during machining. It is

similar to that of surface roughness created on drilled surface by removal of excess material.

Fig 4.8 shows the surface of drilled work pieces using different cutting fluid and also at dry

cutting condition. From the figure it can be seen that for the blend of 50% Neem & 50%

Karanja, the work surface is very smooth indicating the wear is less, this may be due to its high

specific heat, optimum Adhesiveness and medium viscosity. These physical properties help

the tool to cut the work piece very smoothly, due to good lubricating property and since heat

transferred to work is less, surface is not brittle so metal removal is smooth and surface

obtained is also smooth. Next to this, the smooth surface is obtained using is Neem, for which

physical properties are next to 50-50 blend. Very rough surface is obtained during dry cutting

as heat flow through work piece is high, resulting in higher brittle surface making it rough and

resulting in higher cutting force for metal removal.

4.9 Micro structural Studies:

Fig. 4.9 shows the micro structure of the specimen before and after drilling. Before drilling it is

observed fine ferrite with uniform distribution of carbon. In case of 50% Neem- 50% Karanja

(d) the maximum temperature is absorbed by the cutting fluid because of which the micro

structure of the metal is same as of the micro structure of the metal before machining (a).

Whereas the microstructures when other cutting fluids are observed to be burnt, uneven

distribution of carbon etc., which is because, the cutting fluid did not carry way the heat

effectively and maximum heat is absorbed by the work piece which can be interrelated with the

hardness value obtained as shown in Fig 4.9 .

(a)Microstructure before Machining



(b)Neem (c)Karanja

(d )50% Neem & 50%

Karanja

(e) 33.3% Neem &

66.6% Karanja

(f)66.6% Neem & 33.3%

Karanja (g) SAE 20W40

(h)Dry

Fig 4. 9 Micro structural of specimen obtained using different cutting fluids and at dry condition

4.10 SEM Analysis:

Fig 4.10 shows SEM images of the specimen before machining and after machining with

different cutting fluids and at dry condition.



before Machining

(a)Neem (b)Karanja

(c)50% Neem & 50% Karanja (d) 33.3% Neem & 66.6%

Karanja



(e)66.6% Neem & 33.3%

Karanja (f) SAE 20W40

(g)Dry

Fig 4. 10 SEM of specimen obtained using different cutting fluids and at dry condition

CONCLUSION


Chapter-5

CONCLUSION

I. The performance of cutting fluid depends on the physical properties. The cutting fluids used

in the present work are Neem, Karanja, blend of both these oils with different percentages and

SAE20W40. The physical properties are been determined for these oils and are given below.

a) Flash point: The highest flash point of 256˚C was recorded for the blend of 50%

Neem- 50% Karanja.

b) Fire point: The blend of 50% Neem- 50% Karanja has got highest fire point of 290˚C.

c) Dynamic Viscosity: Optimum viscosity of 0.01648 N-s/m² was obtained for the blend

of 50% Neem- 50% Karanja.

d) Specific heat: Comparing with Specific heats of other cutting fluids the blend of 50%

Neem- 50% Karanja has got high specific heat of 1.6991KJ/Kg. K.

e) Adhesiveness: The Adhesiveness of the fluid should be optimum, i.e. it should not be

high as the fluid helps the chips in sticking to machined surface through and if it low

fluid flow through the machining zone and will affect the lubricating property. For 50%

Neem- 50% Karanja, the value is 359 g/m2. This value is optimum compared to others

used.

II. Experimental results during machining with various cutting fluids:

a) Cutting force: The cutting force should be less when a good cutting fluid is used. The

cutting force of 169.23N was less for the blend of 50% Neem- 50% Karanja.

b) Tool and specimen Temperature: The temperature of tool and specimen was very

less when the blend of 50% Neem- 50% Karanja was used. The temperature of tool was

36.2˚C and the temperature of specimen was 39.1˚C.

c) Hardness: Due to friction the heat flows through the specimen and this heat should be

less if the cutting fluid is effective i.e. cutting fluid should absorb more heat. Properties

of the specimen will vary compared to parent work piece and this change in properties

depends on the heat given to the specimen during machining. For 50% Neem- 50%

CONCLUSION


Karanja, the hardness of machined specimen(79.5 HRB) is very nearer to the value

obtained with un-machined specimen(78 HRB)

d) Study of chips formed: The surface of the work piece depends on the type of chip

formed during machining; If the chips formed are uniform and continuous then the

cutting fluid used is very good resulting in good surface finish. The continuous chips

and uniform were formed for the blend of 50% Neem- 50% Karanja.

e) Color of the chips: The chips formed for the blend of 50% Neem- 50% Karanja were

in uncoloured silver indicating that heat carried by the chip is less. This can also be

observed by the length of the chip which is long and continuous. This type of chip is

formed only when the cutting fluid used is very good.

f) Surface roughness measured for Blend of 50% Neem- 50% Karanja oil is 1.16 µm,

which is less compared to other cutting fluids used.

From the above results it was found that the blend of 50% Neem and 50% Karanja is the best

cutting fluid compared to other cutting fluids used in this work, more over It is environmental

friendly, bio-degradable, non-hazardous and economical.

SCOPE FOR FUTURE WORK


Scope for future work:

1. In the present work, blend of 50 % Neem and 50% Karanja is concluded to be the best

cutting fluid for drilling Mild steel, but the only drawback is that Specific heat is less

compared to Petroleum based cutting fluids used . This can be overcome by adding

some additives , which can be taken as future work

2. Still many other non-edible vegetable oils can be used as cutting fluid and explore their

advantages and disadvantages.


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Application of Vegetable based oils as cutting fluids for various machining

operations -A review

Susmitha.M

1, Sharan .P

1, Jyothi.P.N

2

1 VIII SEM students, Mechanical Engineering, KSSEM

2Professor Dept. of Mechanical Engg. KSSEM . * Email: [email protected]

:

Abstract

Earlier water was used as coolant to absorb the heat during machining and since it resulted in

corrosion, simple oils were used as cutting fluids which performed as both coolant and

lubricant. But now a days cutting operation has become more complex due to more

complicated shaped to be machined and development in the fields of material. Now selection

of cutting fluid is based on type of material to be machined and type of operation to be carried

out. Mineral based cutting fluids are commonly used in the machining industries, but these

oils are not bio degradable, health hazardous and non-renewable. Hence, many researchers are

carrying out research work on application of different types of vegetable oils as cutting fluids

for different machining operation. The present paper provides a review on application of

vegetable based oils used as for different machining operation.

Key words: Vegetable oils; cutting fluids; machining; Biodegradable

1. Introduction:

Cutting fluid, as a component of machining

industry, has been introduced and applied over 100

years. Cutting fluids are used in metal machining for

a variety of reasons such as improving tool life,

reducing work piece and thermal deformation,

improving surface finish and flushing away chips

from the cutting zone.

Practically cutting fluids are classified into four

categories:

Straight oils: Straight oils are non-emulsifiable.

These oils in undiluted form are used in machining

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operations. 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 phosphorous. Straight oils provide the best

lubrications and poor cooling characteristics among

cutting fluids.

Synthetic fluids: synthetic fluids are formulated

from alkaline inorganic and organic compounds

along with additives for corrosion inhibition. They

are generally used in a diluted form. Synthetic fluids

provide the best cooling performance among all

cutting fluids.

Soluble oil fluids: Soluble oil fluids when mixed

with water form an emulsion. The concentrate

consists of emulsifiers and base mineral oil to help

produce a stable emulsion. They provide good

lubrication and heat transfer performance. They are

the least expensive among all cutting fluids.

Semi synthetic fluids: Semi synthetic fluids are

combination of soluble oil fluids and synthetic

fluids. They have characteristics common to both

types.

The basic functions of cutting fluids include the

following four considerations: cooling, lubrication,

corrosion protection and chip removal from

Machining area.

The desirable properties of cutting fluid in general

are:

High thermal conductivity for cooling

Good lubricating qualities

High flash point should not entail a fire

hazard

Must not procedure a gummy or solid

precipitate at ordinary working

temperatures

Be stable against oxidation

Must not promote corrosion or dislocation

of the work material

Must afford some corrosion protection to

nearly formed surfaces

The components of the lubricant must not

become rancid easily

No unpleasant odor must develop from

continued used

Must not cause skin irritation or

contamination

A viscosity that will permit free flow from

the work and dripping from the chips

Process effects of using cutting fluids in machining

include, longer tool life, reduced thermal

deformation of work piece, better surface finish,

Ease of chip and swarf handling.

2. Drawbacks of petroleum based cutting

fluids:

Due to the importance of cutting fluids, significant

issues have been raised in their application,

recycling and disposal. Proper selection and

application can reduce manufacturing cost and

improve productivity on the other hand,

manufacturing failure and wastes can be

experienced by misuse of cutting fluids. And

regarding to the environmental impacts and health

hazards by cutting fluids, recycling and disposal of

cutting fluid are also of great importance. Improper

disposal actions can cause severe health and

environmental problems. These problems gave

provision for the introduction of mineral, vegetable

and animal oils. These oils play an important role in

enhancing various aspects of machining properties,

including corrosion protection, anti-bacterial

protection, lubricity, chemical stability and even

emulsibility.

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3. Vegetable oils

A ―Vegetable oil‖ is a triglyceride extracted from a

plant. Vegetable oils that are solid at room

temperature are sometimes called vegetable fats.

Vegetable oils can be classified in to various ways

depending upon the source, application etc.., oils

can be edible or non-edible in nature. Compared to

mineral oils vegetable oils in general possess high

flash point, high viscosity index, high lubricity and

low evaporative losses. Vegetable oils are extracted

from plants by placing the relevant part of the plant

under pressure, to squeeze the oil out. Oils (edible

or non-edible) may also be extracted from plants by

dissolving parts of plants in water or another

solvent, and distilling the oil, or by infusing parts of

plants in base oil.

Various researchers have proved the worth

of edible vegetable oils viz., coconut oil, palm oil,

soya bean oil, canola oil to be used as ecofriendly

fluid in recent past. But in present situations

harnessing edible oils for lubricants formation

restricts the use due to increased demands catering

the growing population worldwide and local

availability. Non-edible vegetable oils and other tree

borne seeds can prove to be an effective alternative,

although limited research has been done on varieties

like PongamiaPinnata (karanja), Jatrophacurcas

(Ratanjyot) etc., prominently for biofuel

applications and needs focused attention for

fulfilling the environmental friendly lubricant need

their full potential. Castor, Mahua and Neem also

process certain properties which makes them a

promising candidate for such formulations. Non-

edible vegetable oils are renewable and

biodegradable in nature.

Vegetable oils are used as an ingredient (or)

component in many manufacture products. These

oils are particularly suitable as drying oils, and are

used in making paints and other wood treatment

products. Vegetable oils are increasingly being used

in the electrical industry as insulators. As vegetable

oils are not toxic to the environment, biodegradable

if spilled and have high flash and fire points.

However, vegetable oils are less stable chemically,

so they are generally used in systems where they are

not exposed to oxygen. Vegetable oil is being used

to produce biodegradable hydraulic fluid and

lubricant.

Edible vegetable oils: A liquid fat that is capable of

being eaten as a food or food access, like Coconut,

Olive, Soya bean, Sunflower, Palm, Peanut,

Rapeseed, Corn etc. Various countries import edible

for their food requirements. India is the biggest

importer of edible oils in the world. Approximately,

16.6 million tons of edible oils consumed each year

in India. Therefore, edible oil seeds usage for

lubricant needs may not be able to meet domestic

requirements for ever increasing population.

Non edible vegetable oils: As an alternative non

edible vegetable oil and tree borne seeds can prove

to be worthwhile. These products from non-edible

vegetable oils like Neem, castor, Mahua, rice bran,

karanja, Jatropha, and linseed oils which offer better

or at least same performance as petroleum oil based

products besides being less expensive [8, 9]. Non

edible vegetable oils are technically and

environmentally acceptable and easily available

resource for bio lubricants.

4. Current Status — Non Edible Vegetable

Oils:

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Being a tropical country, India is rich in forest

resources having a wide range of trees, which yield

a significant quantity of oilseeds. India is importing

crude petroleum & petroleum products from Gulf

countries. Indian scientists searched for an alternate

to petroleum based lubricant to preserve global

environment and to withstand economic crisis.

Some Non Edible Vegetable Oils Available in India

5. Application of vegetable oil-based

cutting fluids in various Machining

operations

A review of machining operations using vegetable

oil-based cutting fluids using various coolant at

different cutting conditions during turning, drilling,

and milling process, on various work materials like

steel, Aluminium and so on is provided. An

overview of the previous work done by other

researchers includes the studies conducted to

investigate the influence of various vegetable oils as

cutting fluid on different work material are also

presented.

S.A.Lawal et al. [1] carried out a review on the

applicability of vegetable oil based metal working

fluids in machining of ferrous metal. The author

focused on the performance and environmental

impact of these vegetable oils as emulsion and

straight oils for various materials and machining

conditions. Finally concluded that

1. Coconut oil showed the best performance at

cutting speed (90 m/min), depth of cut (1 mm) and

feed rate (0.35 mm/rev) when compared to mineral

oil on turning of AISI 304 austenitic stainless steel.

Surface roughness (Ra) of 4.5 mm and 5.5 mm were

obtained respectively for coconut oil and mineral

oil.

2.Palm oil-based cutting fluids used in milling of

AISI 420 stainless steel was observed to yield

longer tool life of 160.27 min and surface roughness

of 0.31 mm compared to fatty, flood and dry cutting

with 137.74, 39.86 35.16 min toollives and 0.48,

0.29, 0.24 mm surface roughness, respectively.

3. When vegetable oil was applied to turning of

AISI 9310 alloy steel using MQL mode of

application, there was remarkable improvement of

metal removal rate (MRR), that is, productivity.

High productivity means that higher feed rate was

achieved when vegetable-oil-based metalworking

fluid was used. Surface roughness values of 4.0, 5.0

and 5.5 mm were obtained for vegetable-oil, wet

and dry cutting, respectively, at cutting velocity of

334 m/min and feed rate of 0.18 mm/rev.

Sharafadeen Kunle Kolawale et al. [2] evaluated

performances of palm oil and ground nut oil when

compared with that of mineral oil based cutting fluid

during machining operation of mild steel. Palm oil

gave the overall highest thickness of 0.27mm

probably due to its better lubricating property.

Based on these results, ground nut oil and palm oil

are being recommended as variable alternative

lubricants to the mineral oil during machining of

mild steel. It was found that Viscosity of groundnut

oil-based sample was lowest and the range was

closest even at very high temperature. Low viscosity

means high viscosity index and the tendency to be

fluidic at high value of working temperature.

Jitendra Kumar Chandrakar et al. [3] in their

research showed that lubricants provide smooth

operation between movable parts of all machines. It

maintains the reliability of machine functions and

reduces the risk of failures. Vegetable bio lubricants

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are non-toxic, degradable, and renewable also

possess good lubricating properties.

Table 1:

In his work, he reviewed papers on edible oils as

cutting fluids. While in few papers non-edible oils

such as castor, karanja, mahua were used and

proved to have a great potential as lubricant for

some of the machining operations.

Ahmad Fairuz Mansor, et.al. [4] Investigated Chip

Formation and Tool Wear in Drilling Process Using

Various Types of Vegetable-Oil Based Lubricants.

This research paper represents the machinability of

using several possible vegetable oils as cutting fluid

in term of chip formation and tool wear during

drilling operation on stainless steel, AISI 316. The

performance of the vegetable oils; palm, sesame,

olive and coconut oils were compared under

minimum quantity lubrication (MQL) technique.

The result reported that the coconut oil indicates the

best machinability in term of highest and uniform

chip thickness and least wear on the drill bit under

same condition with others. These performances are

followed by palm, olive and sesame oil. In

additional, the viscosity measurement indicates that

coconut oil has the lowest value which can

possesses better fluidity and faster cooling capacity

than other oils. Overall, coconut oil is recommended

as viable alternative lubricants during drilling of

stainless steel.

EmelKuram, et.al [5] studied the Effects of

vegetable-based cutting fluids on the wear in

drilling. This work focused on both formulation of

vegetable-based cutting fluids (VBCFs) and

machining with vegetable-based cutting fluids.

Performances of three VBCFs developed from crude

sunflower oil, refined sunflower oil, refined canola

oil and commercial semi-synthetic cutting fluid are

compared in terms of tool wear, thrust force and

surface roughness during drilling of AISI 304

austenitic stainless steel with HSSE tool.

Experimental results show that canola based cutting

fluid gives the best performance due to its higher

lubricant properties with respect to other cutting

fluids at the constant cutting conditions (spindle

speed of 750 rpm and feed rate of 0.1 mm/rev)

M. Venkata Ramana et al. [6] discussed about

specific study and application of bio-asserted cutting

fluid such as palm oil and turning of Titanium alloy

(Ti-6Al-4V) and application of solid lubricant

mixture like boric acid in palm oil on turning of Ti-

6Al-4V alloy is studied. A total of five process

parameters with three levels for each are chosen as

the control factors such that the levels are

sufficiently covers wide range. Based on the results

of the experimental investigations, the following

conclusions are drawn:

1. Machining with palm oil is found to be better

than dry and palm oil with solid lubricant boric acid

as cutting fluid.

Types of fluid Biodegradability (%)

Mineral Oil 20-30

Vegetable oil 95-98

Esters 75-100

Polyols 75-100

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2. The optimal and best combination values for

minimizing surface roughness are palm oil, cutting

speed at 79 m/min, feed rate at 0.206 mm/rev, depth

of cut at 1.0mm and CVD coated tool.

M.M.A. Khan et al. [7] investigated the effects of

minimum quality lubrication (MQL) by vegetable

oil based cutting fluid under turning operation of

low alloy steel AISI 9310.The results were

compared with completely dry and wet machine in

terms of tool- chip interface temperature, chip

formation mode, tool wear and surface roughness.

Results show that MQL provides environmental

friendliness and improves the machinability

characteristics.

Conclusion:

1. Petroleum Based oils are widely used for

machining operations ,but these oils have

disadvantage like non-bio degradable, health

hazardous and non-renewable, which made the

the researchers to focus on using vegetable based

oils as cutting fluids.

2. Vegetable based oils which have got advantages

like bio-degradable, eco-friendly and renewable

source can be used as alternative cutting fluid.

3. Edible oils like coconut oil, groundnut oil,

sunflower oil etc., gave best results compared to

petroleum based oils but this restricts the use due

to increased demands catering the growing

population worldwide and local availability.

4. Non edible oils like Neem, castor, Mahua, rice

bran, karanja, Jatropha, and linseed oils which

offer better or at least same performance as

petroleum oil based products besides being less

expensive, hence in future performance of these

oils as cutting fluids can be evaluated .

References:

[1] S.A. Lawal, I.A. Choudhury , Y. Nukman,

Application of vegetable oil-based metalworking

fluids in machining ferrous metals—A review,

International Journal of Machine Tools and

Manufacture(2011),

doi:10.1016/j.ijmachtools.2011.09.003.

[2] Sharafadeen Kunle Kolawole et al, Performance

Evaluation of Vegetable Oil-Based Cutting Fluids in

Mild Steel Machining, Chemistry and Materials

Research, ISSN 2224- 3224 (Print) ISSN 2225-

0956 (Online), Vol.3 No.9, 2013, page 35-45.

[3] Jitendra Kumar Chandrakar et al, The prospects

of vegetable based oils as metal cutting fluids in

manufacturing application, IOinternational journel

of engineering research & technology (IJERT)

ISSN: 2278-0181, vol.3 Issue 5, May-2014.

[4] M.A. Fairuz, M.J. Nurul Adlina, A. I. Azmi,

M.R.M. Hafiezal, K.W. Leong, "Investigation of

Chip Formation and Tool Wear in Drilling Process

Using Various Types of Vegetable-Oil Based

Lubricants", Applied Mechanics and Materials,

Vols. 799-800, pp. 247-250, 2015.

[5] Emel Kuram, M. Huseyin Cetin, Babur

Ozcelik & Erhan Demirbas, Performance Analysis

of Developed Vegetable-Based Cutting Fluids by D-

Optimal Experimental Design in Turning Process,

International Journel of Computer Integrated

Manufacturing, Volume 25, Issue 12, 2012.

[6] M. VENKATA RAMANA et al, Effect of

Process Parameters on Surface Roughness in

Turning of Titanium Alloy under Different

Conditions of Lubrication, Recent Advances in

Robotics, Aeronautical and Mechanical

http://www.tandfonline.com/author/Kuram%2C+Emel

http://www.tandfonline.com/author/Cetin%2C+M+Huseyin

http://www.tandfonline.com/author/Ozcelik%2C+Babur

http://www.tandfonline.com/author/Ozcelik%2C+Babur

http://www.tandfonline.com/author/Demirbas%2C+Erhan

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Engineering, ISBN: 978-1-61804-185-2, page 83-

91.

[7] M. M. A. Khan et al, Effects of minimum

quantity lubrication on turning AISI 9310 alloy steel

using vegetable oilbased cutting fluid, Journal of

Materials Processing Technology 209 (2009) 5573–

5583, May 2009, page 5573- 5583.

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