Report on Summer Research InternshipOn

Machining With Eco-friendly Cutting FluidsCompleted At

Indian Institute Of Technology, GuwahatiUnder Dr. M. Ravi Sankar

Duration: May 24th 2013 to July 11th 2013

Submitted To: Submitted By:Prof. O.P. Arora Prashant BhushanProf. R.K. Mathur Roll No. 11001184090Department Of Mechanical Engg. Deptt. Of Mechanical Engg.Bhagwant University, Ajmer Bhagwant University, Ajmer

Bhagwant University, Ajmer

In 21st century, keeping in view of environment protection awareness under law and regulation, Eco-Friendly Cutting Fluids has become a general trends..

During machining process cutting fluids are required to reduce the cutting forces, lowering cutting temperature of working tools.

This helps in prolong tool life and enhances machining efficiency and surface finish quality during machining.

These fluids generally comprise of Vegetables Oils, Bio-Cutting Fluids and some Chemically Synthesized Fluids.

Introduction

Process Performance

• Heat transfer performance • Lubricating performance• Chips flushing• Fluid mist generation• Fluid carry-off in chips• Corrosion inhibition

Cost performance Environmental performance Health hazard performance

Selection Criteria for Eco-friendly Fluids:

These fluids are friendly to nature and don’t pollute the environment.

These fluids are also friendly with the operators and the machine parts.

These are easily available and basically derived from the natural sources.

As compared to chemically aided fluids these fluids give better surface finish.

These fluids also give better condition to the workers and the engineers involved in operation under this.

Why do we use Eco-Friendly Cutting Fluids?

1.Vegetable Oil: These oils are renewable, biodegradable and non-

toxic in nature with high viscosity and high flash point.

It have high tendency to get metabolized by microorganism that alleviates problems faced by workers such as skin cancer.

These vegetables oils are life cycle based on renewable resources which is represented as:

Various Eco-Friendly Cutting Fluids:

Fatty Acid, GlycerolFormulation

Consumers Products

Use

Waste, Waste Water

DisintegrationCO2, Water

Photosynthesis

Assimilation

Biomass

Extraction

Plant Oil, Fats, Tallow

Production

Fig.: Life cycle of chemical products based on renewable resources

As per selection vegetable oil comprise of following oils:

Soybean oils Coconut oils Sunflower oils Jatropha oils Castor oils Jojoba oils Karanja seed oils Neem oils Tall oils

18% oil (0.5%Lecithin)

14% Moisture, ash, other

15% Insoluble Carbohydrate (dietary fiber)

38% Protein

15% Soluble carbohydrate

Fig.: Composition of Soybean

The use of vegetable oils don’t give better machining operation due to lower flash point as it gives greater heat generation and mist formation. Due to this Bio-Cutting Fluids are used. These are chemically modified which are also eco-friendly to nature.

Some of Bio-Cutting Fluids are:

Ester oil Synthetic ester oil Emulsified synthetic oil PanTerra MMEP oil

Bio-Cutting Fluids:

Liquid nitrogen is liquid at low temperature and made commercially from cryogenic distillation.

It is non-inflammable and slightly lighter than air and partially soluble in water.

The best benefit is that it is inert in nature and doesn’t react with many materials.

It replaces many petro-chemical based oils as it is friendly for workers and public.

It is widely used to control process temperature in thermal spray coating.

Liquid Nitrogen as Cutting fluid:

Ionized Air cooling system:Rough tolerance

Oxide layerChips

BlankTool Direction

400O

600O500O

200O340O 350O

Ionized air coolant system

Fig.: Technique of cooling with ionized air.

400O

850O

800O

750O

This system is also know as ECO-COOLING SYSTEM.

This system is comprise of:1. The tube from

compressed air unit.

2. Controller unit

3. Feeding system of the ionized air flow.

Water vapour as coolant & lubricant:

Water vapour generator

Temperature control system

Quadric heater

Control valve

Nozzle

Fig.5: Vapour generator and vapor feeding system

o In this system, the water vapor generator and vapour feeding system are developed in which jet flow parameter such as pressure, temperature, flow velocity and humidity and cooling distance are controlled.

o It is employed for high speed based on a new concept of having a high lubricity.

o It also gives an excellent penetration performance and forming a low shearing strength lubrication layer.

o This method is applied to industries for improving operation environment and low cost processing.

Contd….

Dielectric Fluid as coolant:

Moving Wire

Dielectric Fluid

Work piece

Fig.: Wire EDM with the use of dielectric fluid

Dielectric fluids don’t conduct electric current under normal condition.

When there is electric breakdown, it heals self without any aid of external agency.

These fluids serve as a spark conductor in the spark gap between tool and work piece.

These fluids also provide electric insulation, suppress corona and arching and also serve as a coolant.

These fluids are mostly used in the electric discharge machining operations and also used as a liquid for transformer cooling.

Contd….

1. Ecoline Cutting oil2. Hazfree chain saw and cutting oil 3. Bio aluminum and many more.

The various operation carried out using these oils:1) Turning2) Facing3) Drilling4) Milling5) knurling

Some market available Eco-friendly cutting oils:

The use of petroleum based oils as coolant and lubricant have become more problematic in terms of both employee health and environmental pollution. The use of vegetable oils as cutting fluid play an important role in this regards. Some others fluids such as liquid nitrogen, CO2 liquid and water vapor are also the best candidates to place of the petroleum based synthetic oils. A new cooling system i.e. Ionized air cooling system is one of the best substitute for the same.

Conclusion:

Junyan Liu, Rongdi Han, Yongfeng Sun Department of Mechanical Manufacture and

Automation, International Journal of Machine Tools & Manufacture 45 (2005) 687–694.

M.A. Maleque, H.H. Masjuki and S.M. Sapuan, Industrial Lubrication and Tribology,

Vegetable- based biodegradable lubricating oil additives, vol.55. Issue Number3,

pp.137-143, 2003.

Y.M. Shashidhara and S.R.Jayaram, Tribology International, Vegetable oils as a

potential cutting fluid - An evolution, 43 (2010), pp.1073-1081.

K.R. Sathwik Chatra, N.H. Jayadas and Satish V. Kailas, Natural oil - based lubricants,

Green Tribology, Green Energy and Technology 2012, pp.287-328.

Podgorkov V.V., Method of cutting in application, in Russia,Patent of USSR 1549721

MCI B23Q, 1992.

References: