TERM PAPER OF MEC-104

8/8/2019 TERM PAPER OF MEC-104

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Term Paper Review

on MEC-104

TOPIC-Importance of cutting fluidsand lubrication in differentmanufacturing process.

Name-Raushan Sudhanshu

Sec-B4902

Roll-B4902B35

Regd-10901326

Submitted To:-Mr.Rakesh Kumar How to do it production drawings

The third SolidWorks tutorial explains how to create a drawing from a SolidWorkspart. Use the

sheet format on my website. Most of the work is done for you by SolidWorks cross sections and


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detailed views are quick to produce, but you will need to re-order and add anddelete dimensions to

make your drawing clear. Use you British Standard to make sure everythingmeets BS 8888.

I have included the beginnings of a production drawing overleaf. I have used across-section, but

further detailed views might be necessary, e.g. a detail of the crankcase studholes/grooves would

help in interpreting the drawing. My dimensioning is not complete. SolidWorks willautomatically

produce very messy dimensions, using all those you have specified in yourSolidWorks model. While

you might have needed a dimension in your model, it may not be necessary onthe drawing consult

the section on dimensioning in your British Standard carefully.


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Cutting fluid Introduction

Thin-wall milling of aluminum using a water-based cutting fluid on the millingcutter .

Cutting fluids are various fluids that are used in machining to cool and lubricatethe cutting tool. There are various kinds of cutting fluids, which include oils, oil-water emulsions , pastes, gels, and mists. They may be made from petroleumdistillates, animal fats, plant oils, or other raw ingredients. Depending on contextand on which type of cutting fluid is being considered, it may be referred to ascutting fluid , cutting oil , cutting compound , coolant , or lubricant .

Every kind of machining (e.g., turning , boring , drilling , milling , broaching ,

grinding , sawing , shaping , planing , reaming , tapping ) can potentially benefit fromone kind of cutting fluid or another, depending on workpiece material. ( Cast iron and brass are usually machined dry. Interrupted cuts such as milling with carbidecutters are usually recommended to be used dry due to damage to the cutterscaused by thermoshock.)

Mechanisms of action

Cooling Metal cutting operations involve generation of heat due to friction between thetool and the pieces and due to energy lost deforming the material. Thesurrounding air alone is a rather poor coolant for the cutting tool, because therate of heat transfer is low. Ambient-air cooling is adequate for light cuts withperiods of rest in between, such as are typical in maintenance, repair andoperations (MRO) work or hobbyist contexts. However, for heavy cuts andconstant use, such as in production work, more heat is produced per time periodthan ambient-air cooling can remove. It is not acceptable to introduce long idleperiods into the cycle time to allow the air-cooling of the tool to "catch up" whenthe heat-removal can instead be accomplished with a flood of liquid, which can"keep up" with the heat generation.

Lubrication at the tool-chip interface Besides cooling, cutting fluids also aid the cutting process by lubricating theinterface between the tool's cutting edge and the chip. By preventing friction atthis interface, some of the heat generation is prevented. This lubrication alsohelps prevent the chip from being welded onto the tool, which interferes withsubsequent cutting.

EP additives are often added to cutting fluids.

Delivery methods
http://docs.google.com/wiki/Aluminumhttp://docs.google.com/wiki/Milling_cutterhttp://docs.google.com/wiki/Milling_cutterhttp://docs.google.com/wiki/Machininghttp://docs.google.com/wiki/Emulsionhttp://docs.google.com/wiki/Turninghttp://docs.google.com/wiki/Boring_(manufacturing)http://docs.google.com/wiki/Drillinghttp://docs.google.com/wiki/Milling_machinehttp://docs.google.com/wiki/Broach_(metalwork)http://docs.google.com/wiki/Grinding_machinehttp://docs.google.com/wiki/Sawinghttp://docs.google.com/wiki/Shaperhttp://docs.google.com/wiki/Planer_(metalworking)http://docs.google.com/wiki/Reamerhttp://docs.google.com/wiki/Tap_and_diehttp://docs.google.com/wiki/Cast_ironhttp://docs.google.com/wiki/Brasshttp://docs.google.com/wiki/Heathttp://docs.google.com/wiki/Maintenance,_repair_and_operationshttp://docs.google.com/wiki/Maintenance,_repair_and_operationshttp://docs.google.com/wiki/EP_additivehttp://docs.google.com/wiki/Milling_cutterhttp://docs.google.com/wiki/Milling_cutterhttp://docs.google.com/wiki/Machininghttp://docs.google.com/wiki/Emulsionhttp://docs.google.com/wiki/Turninghttp://docs.google.com/wiki/Boring_(manufacturing)http://docs.google.com/wiki/Drillinghttp://docs.google.com/wiki/Milling_machinehttp://docs.google.com/wiki/Broach_(metalwork)http://docs.google.com/wiki/Grinding_machinehttp://docs.google.com/wiki/Sawinghttp://docs.google.com/wiki/Shaperhttp://docs.google.com/wiki/Planer_(metalworking)http://docs.google.com/wiki/Reamerhttp://docs.google.com/wiki/Tap_and_diehttp://docs.google.com/wiki/Cast_ironhttp://docs.google.com/wiki/Brasshttp://docs.google.com/wiki/Heathttp://docs.google.com/wiki/Maintenance,_repair_and_operationshttp://docs.google.com/wiki/Maintenance,_repair_and_operationshttp://docs.google.com/wiki/EP_additivehttp://docs.google.com/wiki/Aluminum


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Every conceivable method of applying cutting fluid (e.g., flooding, spraying,dripping, misting, brushing) can be used, with the best choice depending on theapplication and the equipment available. For many metalcutting applications theideal would be high-pressure, high-volume pumping to force a stream of fluiddirectly into the tool-chip interface, with walls around the machine to contain thesplatter and a sump to catch, filter, and recirculate the fluid. This type of system

is commonly employed, especially in manufacturing. It is often not a practicaloption for MRO or hobbyist metalcutting, where smaller, simpler machine toolsare used. Fortunately it is also not necessary in those applications, where heavycuts, aggressive speeds and feeds , and constant, all-day cutting are not vital.

Types of cutting fluid

Liquids There are generally three types of liquids: mineral, semi-synthetic, and synthetic.Semi-synthetic and synthetic cutting fluids try to blend the best properties of oil

into the best properties of water. They basically achieve this by allowing oil toemulsify into water. Some of these properties are: rust inhibition, tolerance of awide range of water hardness (maintain pH stability around 9 to 10), ability towork with many metals, resist thermal breakdown, and environmental safety. [1]

Water is a great conductor of heat but has drawbacks as a cutting fluid. It boilseasily, promotes rusting of machine parts, and does not lubricate well. Therefore,other ingredients are necessary to create an optimal cutting fluid.

Mineral coolants, which are petroleum-based, began in the late 1800s. They varyfrom the thick, dark, sulfur-rich cutting oils used in heavy industry to light, clearoils.

Semi-synthetic coolants are an emulsion or microemulsion of water with mineraloil. They began in the 1930s. A typical CNC usually uses emulsified coolant, whichconsists of a small amount of oil emulsified into a larger amount of water throughthe use of a detergent.

Synthetic coolants originated in the late 1950s and are usually water-based.

A hand-held refractometer is used to determine the mix ratio (also calledstrength) of water soluble coolants to verify effectiveness. Numerous other testequipment are used to determine such things as acidity, and amount of conductivity.

Pastes or gels Cutting fluid may also take the form of a paste or gel when used for someapplications, in particular hand operations such as drilling and tapping .

Mists Some cutting fluids are used in mist ( aerosol ) form, although breathing such alubricant in mist form is a severe and immediate health hazard.
http://docs.google.com/wiki/Speeds_and_feedshttp://docs.google.com/wiki/Mineralhttp://docs.google.com/wiki/Microemulsionhttp://docs.google.com/wiki/Synthetichttp://docs.google.com/wiki/Refractometerhttp://docs.google.com/wiki/Drillhttp://docs.google.com/wiki/Taps_and_dieshttp://docs.google.com/wiki/Aerosolhttp://docs.google.com/wiki/Speeds_and_feedshttp://docs.google.com/wiki/Mineralhttp://docs.google.com/wiki/Microemulsionhttp://docs.google.com/wiki/Synthetichttp://docs.google.com/wiki/Refractometerhttp://docs.google.com/wiki/Drillhttp://docs.google.com/wiki/Taps_and_dieshttp://docs.google.com/wiki/Aerosol


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Safety Cutting fluids have been associated with skin rashes, dermatitis , esophagitis , lungdisease, and cancer. These problems result from either toxicity or bacterial orfungal contamination.

Metalworking fluids often contain substances such as biocides , corrosion

inhibitors , metal fines, tramp oils , and biological contaminants. Inhalation of cutting fluid aerosols may cause irritation of the throat, nose, and lungs and hasbeen associated with chronic bronchitis , asthma , hypersensitivity pneumonitis (HP), and worsening of pre-existing respiratory problems. Skin exposure mayresult from touching contaminated surfaces, handling parts and equipment,splashing fluids, and aerosol mist settling on the skin. Skin contact with cuttingfluids may cause allergic contact dermatitis, irritant contact dermatitis, andoccupational ("oil") acne. [2]

Safer formulations provide a natural resistance to tramp oils allowing improvedfiltration separation without removing the base additive package. Ventilation,splash guards on machines, and personal protective equipment can mitigatehazards related to cutting fluids. [3]

Bacterial growth is predominant in semi-synthetic and synthetic fluids. Tramp oilalong with human hair or skin oil are some of the debris during cutting whichaccumulates and forms a layer on the top of the liquid, anaerobic bacteriaproliferate due to a number of factors. An early sign of the need for replacementis the "Monday-morning smell" (due to lack of usage from Friday to Monday).Antiseptics are sometimes added to the fluid to kill bacteria. Such use must bebalanced against whether the antiseptics will harm the cutting performance,workers' health, or the environment. Maintaining as low a fluid temperature aspractical will slow the growth of microorganisms. [3]

Lubricants Introduction A lubricant (sometimes referred to as "lube") is a substance (often a liquid)introduced between two moving surfaces to reduce the friction between them,improving efficiency and reducing wear . They may also have the function of dissolving or transporting foreign particles and of distributing heat.

One of the single largest applications for lubricants, in the form of motor oil , is to

protect the in motor vehicles and powered equipment. Typically internal combustion engines lubricants contain 90% base oil (most oftenpetroleum fractions, called mineral oils ) and less than 10% additives. Vegetableoils or synthetic liquids such as hydrogenated polyolefins , esters , silicones ,fluorocarbons and many others are sometimes used as base oils. Additives deliverreduced friction and wear, increased viscosity , improved viscosity index,resistance to corrosion and oxidation , aging or contamination, etc.
http://docs.google.com/wiki/Dermatitishttp://docs.google.com/wiki/Esophagitishttp://docs.google.com/wiki/Biocidehttp://docs.google.com/wiki/Corrosion_inhibitorhttp://docs.google.com/wiki/Corrosion_inhibitorhttp://docs.google.com/wiki/Tramp_oilhttp://docs.google.com/wiki/Tramp_oilhttp://docs.google.com/wiki/Chronic_bronchitishttp://docs.google.com/wiki/Asthmahttp://docs.google.com/wiki/Hypersensitivity_pneumonitishttp://docs.google.com/wiki/Bacteriahttp://docs.google.com/wiki/Antiseptichttp://docs.google.com/wiki/Frictionhttp://docs.google.com/wiki/Efficient_energy_usehttp://docs.google.com/wiki/Wearhttp://docs.google.com/wiki/Motor_oilhttp://docs.google.com/wiki/Internal_combustion_enginehttp://docs.google.com/wiki/Petroleumhttp://docs.google.com/wiki/Mineral_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Polyolefinhttp://docs.google.com/wiki/Esterhttp://docs.google.com/wiki/Siliconehttp://docs.google.com/wiki/Fluorocarbonhttp://docs.google.com/wiki/Viscosityhttp://docs.google.com/wiki/Corrosionhttp://docs.google.com/wiki/Oxidationhttp://docs.google.com/wiki/Dermatitishttp://docs.google.com/wiki/Esophagitishttp://docs.google.com/wiki/Biocidehttp://docs.google.com/wiki/Corrosion_inhibitorhttp://docs.google.com/wiki/Corrosion_inhibitorhttp://docs.google.com/wiki/Tramp_oilhttp://docs.google.com/wiki/Tramp_oilhttp://docs.google.com/wiki/Chronic_bronchitishttp://docs.google.com/wiki/Asthmahttp://docs.google.com/wiki/Hypersensitivity_pneumonitishttp://docs.google.com/wiki/Bacteriahttp://docs.google.com/wiki/Antiseptichttp://docs.google.com/wiki/Frictionhttp://docs.google.com/wiki/Efficient_energy_usehttp://docs.google.com/wiki/Wearhttp://docs.google.com/wiki/Motor_oilhttp://docs.google.com/wiki/Internal_combustion_enginehttp://docs.google.com/wiki/Petroleumhttp://docs.google.com/wiki/Mineral_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Polyolefinhttp://docs.google.com/wiki/Esterhttp://docs.google.com/wiki/Siliconehttp://docs.google.com/wiki/Fluorocarbonhttp://docs.google.com/wiki/Viscosityhttp://docs.google.com/wiki/Corrosionhttp://docs.google.com/wiki/Oxidation


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Lubricants such as 2-cycle oil are also added to some fuels . Sulfur impurities infuels also provide some lubrication properties, which has to be taken in accountwhen switching to a low-sulfur diesel ; biodiesel is a popular diesel fuel additiveproviding additional lubricity.

Non-liquid lubricants include grease , powders (dry graphite , PTFE , Molybdenumdisulfide , tungsten disulfide , etc.), teflon tape used in plumbing, air cushion andothers. Dry lubricants such as graphite, molybdenum disulfide and tungstendisulfide also offer lubrication at temperatures (up to 350 C) higher than liquidand oil-based lubricants are able to operate. Limited interest has been shown inlow friction properties of compacted oxide glaze layers formed at several hundreddegrees Celsius in metallic sliding systems, however, practical use is still manyyears away due to their physically unstable nature.

Another approach to reducing friction and wear is to use bearings such as ballbearings , roller bearings or air bearings , which in turn require internal lubricationthemselves, or to use sound, in the case of acoustic lubrication .

In addition to industrial applications, lubricants are used for many other purposes.

Other uses include bio- medical applications (e.g. lubricants for artificial joints ) andthe use of personal lubricant for sexual purposes.

Purpose

Lubricants perform the following key functions.

Keep moving parts apart Reduce friction Transfer heat Carry away contaminants & debris Transmit power Protect against wear Prevent corrosion Seal for gasses Stop the risk of smoke and fire of objects

Types of lubricants Gas Liquid including emulsions and suspensions

Solid

Greases Adhesive

Gaseous lubricants

Gaseous lubricants have a much lower viscosity and higher compressibilitycompared to liquid lubricants, but the fluid-film principles apply analogeous togases. Some examples for gaseous lubricants are air (used in fluid bearings ),technical gases, steam or liquid-metal vapours.
http://docs.google.com/wiki/2-cycle_oilhttp://docs.google.com/wiki/Fuelhttp://docs.google.com/wiki/Sulfurhttp://docs.google.com/wiki/Diesel_fuelhttp://docs.google.com/wiki/Biodieselhttp://docs.google.com/wiki/Grease_(lubricant)http://docs.google.com/wiki/Graphitehttp://docs.google.com/wiki/Polytetrafluoroethylenehttp://docs.google.com/wiki/Molybdenum_disulfidehttp://docs.google.com/wiki/Molybdenum_disulfidehttp://docs.google.com/wiki/Tungsten_disulfidehttp://docs.google.com/wiki/Dry_lubricanthttp://docs.google.com/wiki/Compacted_oxide_glaze_layerhttp://docs.google.com/wiki/Bearing_(mechanical)http://docs.google.com/wiki/Ball_bearinghttp://docs.google.com/wiki/Ball_bearinghttp://docs.google.com/wiki/Roller_bearinghttp://docs.google.com/wiki/Air_bearinghttp://docs.google.com/wiki/Acoustic_lubricationhttp://docs.google.com/wiki/Medicalhttp://docs.google.com/wiki/Replacement_jointhttp://docs.google.com/wiki/Personal_lubricanthttp://docs.google.com/wiki/Gashttp://docs.google.com/wiki/Liquidhttp://docs.google.com/wiki/Solidhttp://docs.google.com/wiki/Grease_(lubricant)http://docs.google.com/wiki/Adhesivehttp://docs.google.com/wiki/Fluid_bearinghttp://docs.google.com/wiki/2-cycle_oilhttp://docs.google.com/wiki/Fuelhttp://docs.google.com/wiki/Sulfurhttp://docs.google.com/wiki/Diesel_fuelhttp://docs.google.com/wiki/Biodieselhttp://docs.google.com/wiki/Grease_(lubricant)http://docs.google.com/wiki/Graphitehttp://docs.google.com/wiki/Polytetrafluoroethylenehttp://docs.google.com/wiki/Molybdenum_disulfidehttp://docs.google.com/wiki/Molybdenum_disulfidehttp://docs.google.com/wiki/Tungsten_disulfidehttp://docs.google.com/wiki/Dry_lubricanthttp://docs.google.com/wiki/Compacted_oxide_glaze_layerhttp://docs.google.com/wiki/Bearing_(mechanical)http://docs.google.com/wiki/Ball_bearinghttp://docs.google.com/wiki/Ball_bearinghttp://docs.google.com/wiki/Roller_bearinghttp://docs.google.com/wiki/Air_bearinghttp://docs.google.com/wiki/Acoustic_lubricationhttp://docs.google.com/wiki/Medicalhttp://docs.google.com/wiki/Replacement_jointhttp://docs.google.com/wiki/Personal_lubricanthttp://docs.google.com/wiki/Gashttp://docs.google.com/wiki/Liquidhttp://docs.google.com/wiki/Solidhttp://docs.google.com/wiki/Grease_(lubricant)http://docs.google.com/wiki/Adhesivehttp://docs.google.com/wiki/Fluid_bearing


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Liquid lubricants

Liquid lubricants may be characterized in many different ways. One of the mostcommon ways is by the type of base oil used. Following are the most commontypes.

Lanolin (wool grease, natural water repellant)

Water Mineral oils Vegetable (natural oil) Synthetic oils Other liquids

Lanolin

A natural water repellent, lanolin is derived from sheep wool grease, and is analternative to the more common petro-chemical based lubricants. This lubricant isalso a corrosion inhibitor, protecting against rust, salts, and acids.

Water

Water can be used on its own, or as a major component in combination with oneof the other base oils. Commonly used in engineering processes, such as millingand lathe turning.

Mineral oil

This term is used to encompass lubricating base oil derived from crude oil . TheAmerican Petroleum Institute (API) designates several types of lubricant base oil

Grease The term grease is used to describe a number of semisolid lubricants possessinga higher initial viscosity than oil . Although the word grease is also used todescribe rendered fat of animals, in the context of lubricants, it typically applies toa material consisting of a calcium , sodium or lithium soap base emulsified withmineral or vegetable oil

Adhesive

Nitrocellulose adhesive outside a tube

For the band, see Adhesive (band) . "Glue" redirects here. For other uses, see Glue (disambiguation) .

Adhesive or glue is a compound in a liquid or semi-liquid state that adheres orbonds items together. Adhesives may come from either natural or synthetic sources. Some modern adhesives are extremely strong, and are becomingincreasingly important in modern construction and industry. The types of materials that can be bonded using adhesives are virtually limitless, but they areespecially useful for bonding thin materials. Adhesives usually require a controlled
http://docs.google.com/wiki/Synthetic_oilhttp://docs.google.com/wiki/Sheephttp://docs.google.com/wiki/Crude_oilhttp://docs.google.com/wiki/American_Petroleum_Institutehttp://docs.google.com/wiki/Quasi-solidhttp://docs.google.com/wiki/Lubricanthttp://docs.google.com/wiki/Viscosityhttp://docs.google.com/wiki/Oilhttp://docs.google.com/wiki/Rendering_(food_processing)http://docs.google.com/wiki/Calciumhttp://docs.google.com/wiki/Sodiumhttp://docs.google.com/wiki/Lithiumhttp://docs.google.com/wiki/Lithiumhttp://docs.google.com/wiki/Soaphttp://docs.google.com/wiki/Emulsionhttp://docs.google.com/wiki/Mineral_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Adhesive_(band)http://docs.google.com/wiki/Glue_(disambiguation)http://docs.google.com/wiki/Adhesionhttp://docs.google.com/wiki/Chemical_synthesishttp://docs.google.com/wiki/Synthetic_oilhttp://docs.google.com/wiki/Sheephttp://docs.google.com/wiki/Crude_oilhttp://docs.google.com/wiki/American_Petroleum_Institutehttp://docs.google.com/wiki/Quasi-solidhttp://docs.google.com/wiki/Lubricanthttp://docs.google.com/wiki/Viscosityhttp://docs.google.com/wiki/Oilhttp://docs.google.com/wiki/Rendering_(food_processing)http://docs.google.com/wiki/Calciumhttp://docs.google.com/wiki/Sodiumhttp://docs.google.com/wiki/Lithiumhttp://docs.google.com/wiki/Soaphttp://docs.google.com/wiki/Emulsionhttp://docs.google.com/wiki/Mineral_oilhttp://docs.google.com/wiki/Vegetable_oilhttp://docs.google.com/wiki/Adhesive_(band)http://docs.google.com/wiki/Glue_(disambiguation)http://docs.google.com/wiki/Adhesionhttp://docs.google.com/wiki/Chemical_synthesis


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temperature to cure or set . They can be electrically and thermally conductive ornonconductive

Environmental impact

Old, used cutting fluid must be disposed of when it is fetid or when it is chemicallydegraded and has lost its performance. As with used motor oil or other wastes, itsimpact on the environment should be mitigated. Legislation and regulation specifyhow this mitigation should be achieved. Enforcement is the most challengingaspect. Modern cutting fluid disposal may involve techniques such asultrafiltration using polymeric or ceramic membranes which concentrates thesuspended and emulsified oil phase
http://docs.google.com/wiki/Curing_(chemistry)http://docs.google.com/wiki/Solidhttp://docs.google.com/wiki/Ultrafiltrationhttp://docs.google.com/wiki/Curing_(chemistry)http://docs.google.com/wiki/Solidhttp://docs.google.com/wiki/Ultrafiltration

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TERM PAPER OF MEC-104