Performance Analysis Of Evaluation Between Oil Based Coolant And Combination Of Oil Based Coolant With Palm Oil On Cutting Surface In Turning Operation.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Performance Analysis of Evaluation between

Oil-Based Coolant and Combination of Oil-Oil-Based

Coolant with Palm Oil on Cutting Surface in

Turning Operation

Thesis submitted in accordance with the requirements of the Malaysia Technical University of Malacca for the Bachelor Degree of Manufacturing Engineering in

Manufacturing Process

Mohd Akram Zaki Mohd Sabri

(B050410045)

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UTeM Library (Pind.1/2007)

BORANG PENGESAHAN ST AT US T ESIS*

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

JUDUL:

SESI PENGAJIAN: 2007/ 2008

Saya _____________________________________________________________________ mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di

Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.

3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.

4. **Sila t andakan (√)

Performance Analysis of Evaluation between Oil-Based Coolant and Combination of Oil-Based Coolant with Palm Oil on Cutting Surface in Turning Operation

MOHD AKRAM ZAKI MOHD SABRI

Disahkan ol eh:

(TANDATANGAN PENULIS) Alamat Tet ap:

LOT 981, Bat u 8 1/ 4, Jalan Padang Serai, 09600, Lunas, Kulim, Kedah Darul Aman

(TANDATANGAN PENYELIA) Cop Rasmi:

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan) (Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Mal aysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

TIDAK TERHAD TERHAD

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DECLARATION

I hereby, declared this thesis entitled “Performance Analysis Of Evaluation Between Oil-Based Coolant And Combination Of Oil-Oil-Based Coolant With Palm Oil On Cutting

Surface In Turning Operation” is the results of my own research except as cited in references.

Signature :……….

Author’s Name : MOHD AKRAM ZAKI MOHD SABRI

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APPROVAL

This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing

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

……… (Main Supervisor) (Official Stamp & Date)

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ABSTRACT

This project represents the performance analysis of coolant during turning operation. The analysis is made on the surface finish after machining. Generally, a few types of cutting fluid in market and being used as cutting fluid to the machining process will give a few advantages such as producing a good surface finish. The main purpose of this project is to investigate the performance of palm oil application as compound in coolant whether suitable or not for machining operation especially the turning operation. Other purpose is to compare and identify the best coolant between the oil-based coolant and the combination of oil-based coolant with palm oil in the aspect of surface machining. Experiment is conducted using a carbon steel AISI 1045 as a workpiece material with dimension of.250mm x 50mm. The workpiece is being turned by conventional lathe machine using (FUCHS) bacteriostatic emulsifiable cutting oil mixed with pure palm oil as coolant. The parameters setting such as cutting speed is set differently, 185rpm, 340rpm, 425rpm, and 625rpm. The feed rate is 0.5mm/rev and depth of cut is 0.5mm will remain constant. Surface roughness value is taken through the surface roughness tester and surface texture observation is done using metallurgy microscope. As the result, the palm oil compound will affect the surface machining and decreasing the quality of surface machining. A few factor is identified which will affect the surface roughness which are cutting speed and machining time.

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ABSTRAK

Projek ini menerangkan analisis prestasi cecair penyejuk semasa operasi pemotongan logam jenis larikkan. Analisis tertumpu kepada hasil permukaan yang telah dimesin. Umumnya, terdapat pelbagai jenis cecair penyejuk dan aplikasinya dalam proses memesin akan memberi beberapa kelebihan seperti menghasilkan satu hasil permukaan yang baik. Tujuan utama projek ini dijalankan adalah untuk menyiasat prestasi minyak sawit apabila dicampurkan ke dalam penyejuk untuk mengetahui samada ianya sesuai atau tidak bagi tujuan pemesinan terutama untuk operasi melarik. Tujuan lain projek ini adalah untuk membandingkan dan mengenal pasti penyejuk terbaik antara minyak berasaskan penyejuk sahaja atau gabungan minyak berasaskan penyejuk dengan minyak sawit dalam aspek permukaan yang dimesin. Eksperimen ini menggunakan satu keluli karbon AISI 1045 sebagai bahan kerja berdimensi 250mm x 50mm. Bahan kerja akan dilarik menggunakan mesin larik konvensional dengan aplikasi (FUCHS) bakteriostatik emulsifiable dicampur dengan minyak sawit tulen sebagai penyejuk pemotongan. Parameter kelajuan seperti kelajuan memotong diaturkan secara berbeza- beza iaitu 185rpm, 340rpm, 425rpm, dan 625rpm. Kadar suapan adalah 0.5mm/rev dan kedalaman memotong adalah 0.5mm akan dikekalkan nilainya. Nilai kekasaran permukaan diambil terus daripada penguji kekasaran permukaan dan pemerhatian tekstur permukaan adalah dibuat menggunakan mikroskop metalurgi. Sebagai hasilnya, sebatian minyak sawit akan menjejaskan permukaan memesin dan mengurangkan kualiti permukaan yang dimesin. Beberapa faktor dikenalipasti akan memberi kesan kepada kekasaran permukaan yang adalah kelajuan memotong dan jumlah masa untuk memesin.

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DEDICATION

For my beloved parents, my family and to those who always gives me courage and support for all these times.

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ACKNOWLEDGEMENTS

Alhamdulillah and Thank to Allah S.W.T. with all His Gracious and His Merciful for giving me strength and ability to accomplish this project research successfully. I would like to take the utmost opportunity to express my sincere and gratitude to my supervisor, Mr. Mohamad Nizam bin Ayof, for giving me support and guidance throughout this Final Year Project until this completing project level.

Also the greatest thanks to my beloved parents and family who always pray and give the encouragement while pursuing my research. Their sacrifices are never being forgotten.

Besides, thanks a lot to Prof. Dr. Mohd Razali Bin Muhamad, Dean of Manufacturing Engineering Faculty, Universiti Teknikal Malaysia Melaka,Dr Mohd Rizal Salleh as head of Department of Manufacturing Process, Mr Sivarao, and also Dr Vijay as well as to all lecturers of Faculty of Manufacturing Engineering.

I also would like to convey my biggest appreciation to all FKP technicians for supporting me in accomplishes my final year project without hesitation. All knowledge and experience I gained would not be forgotten.

And last but not least, to all my fellow friends who involves direct or indirectly that always stand strong beside me in giving opinions and supports throughout our relationship, I really thankful and appreciate it. All yours are the most valuable things for the rest of my life.

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Abstract i

Abstrak ii

Dedication iii

Acknowledgement iv

Table of Contents v

List of Figures x

List of Tables xii

List of Abbreviations, Signs, and Symbols xiii

1.0 INTRODUCTION

1.1 Introduction 1

1.2 Problem Statement 3

1. Objectives 4

1.4 Project Scope 5

1.5 Limitation of Scope 5

2.0 LITERITURE REVIEW

2.1 Introduction 6

2.2 Introduction to Cutting Fluids 6

2.2.1 Coolant and Lubricant 8

2.3 Types of Cutting Fluids 9

2.3.1. Soluble oils 9

2.3.2 Straight oils 9

2.3.3 Semi synthetics 10

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2.4 Advantages and Disadvantages According to Types of Cutting Fluids 11

2.4.1 Soluble oils 11

2.4.2 Straight oils 12

2.4.3 Synthetics 13

2.4.4 Semi synthetics 14

2.5 Functions of Cutting Fluids 15

2.6 Cutting Fluids Selection and Applications 16

2.6.1 Selection of Cutting Fluids 16

2.6.2 Cutting Fluids Application Methods 19

2.6.2.1 Manual Application 19

2.6.2.2 Flood Application 19

2.6.2.3 Jet Application 20

2.6.2.4 Mist Application 21

2.7 Benefits of Cutting Fluids 22

2.8 New Development of Cutting Fluids 24

2.8.1 Introduction 24

2.8.2 Cutting Fluid from Vegetable Oil 24

2.8.3 Cutting Fluid from Soy Bean Oil 26

2.9 Palm Oil: A Source from Malaysia to Be Developed 27

2.9.1 Introduction to Palm Oil 27

2.9.1.1 History 27

2.9.1.2 Palm Oil Source 27

2.9.1.3 Palm Oil Composition 28

2.10 Conventional Lathe Machine 29

2.10.1 Introduction to lathe machine 29

2.10.2 Basic Part of Lathe Machine 30

2.10.3 Operation of Lathe Machine 31

2.11.4 Turning Operation 32

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2.11.5.1 Speed 33

2.11.5.2 Feed 34

2.11.5.3 Depth of Cut 34

2.11 Surface Metrology 35

2.11.1 Introduction to Surface Metrology 35

2.11.2 Surface Evaluation 35

2.11.3 Surface Texture 35

2.11.4 Surface Roughness 37

2.11.5 Importance of Surface Characterization 39 3.0 METHODOLOGY

3.1 Introduction 40

3.1.1 Planning 41

3.2 Methodology Flowchart 42

3.3 Selection of Machine / Equipment 43

3.3.1 Conventional Lathe Machine 43

3.3.2 Band Saw 44

3.3.3 Surface Roughness Tester 45

3.3.4 Metallurgy Microscope 46

3.4 Selection of Cutting Fluids 47

3.4.1 Bacteriostatic Emulsifiable Oil (Fuchs) 47

3.5 Selection of Adding Compound 48

3.5.1 Palm Oil 48

3.6 Selection of Workpiece Material 49

3.7 Selection of Cutting Tool 50

3.8 Selection Cutting Parameters 51

3.8.1 Cutting Speed 51

3.8.2 Cutting Time 51

3.8.3 Depth of Cut 51

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3.9 Experiment Procedure 52

3.9.1 Experiment Flowchart 52

3.9.2 Preparation of Workpiece 54

3.9.3 Preparation of Cutting Fluid 55

3.9.4 Preparation of Cutting Tool 56

3.9.5 Machining Parameters 57

3.9.6 Machining Operation and Procedure 59

3.9.7 Surface Roughness Operating Procedure 60 3.9.8 Metallurgy Microscope Operating Procedure 61

4.0 RESULTS

4.1 Introduction 62

4.2 Surface Roughness Result for Bacteriostatic Emulsifiable Cutting Fluids

mixed with Palm Oil 63

4.2.1 Surface Roughness Analysis for Bacteriostatic Emulsifiable Cutting

Fluids mixed with Palm Oil 65

4.3 Surface Roughness Result for Bacteriostatic Emulsifiable Cutting Fluids used

as Comparison Result 68

4.4 Surface Texture Observation 72

4.5 Surface Roughness Comparison between Bacteriostatic Emulsifiable and Bacteriostatic Emulsifiable Cutting Fluids mixed with Palm Oil 77

4.5.1 Comparison of Surface Roughness in the Aspect of Cutting

Speed 77

4.5.2 Comparison of Surface Roughness in the Aspect of Machining Time

5.0 DISCUSSION 85

6.0 CONCLUSION & RECOMMENDATIONS 87

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REFERENCE 89

APPENDICES

APPENDIX A

Gantt chart For PSM 1 Gantt chart For PSM 2 APPENDIX B

Table of Surface Roughness Result APPENDIX C

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LIST OF FIGURES

2.1 A flood method of cutting fluid is applied on the workpiece 20

2.2 A jet method of cutting fluid is applied on the workpiece directed at

the cutting zone 20

2.3 The mist application of cutting fluid is directed at the cutting zone 21

2.4 Lathe machine and parts of lathe machine 29

2.5 Turning operation 33

2.6 Standard terminology and symbol to describe surface finish.

The quantities are given in µin 36

2.7 The Arithmetic mean value, Ra 38

2.8 Coordinate used for surface roughness measurement 38

3.1 Work planning for PSM 41

3.2 Methodology Flowchart 42

3.3 Conventional lathe machine 43

3.4 Band saw 44

3.5 Surface roughness tester 45

3.6 Metallurgy microscope 46

3.7 Bacteriostatic emulsifiable oil (Fuchs) 47

3.8 Palm oil 48

3.9 Mild steel (AISI 1045) 49

3.10 Dimension of the workpiece 49

3.11 HSS cutting tool 50

3.12 Experiment Flowchart 53

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3.15 Cutting tool terminology 56

3.16 Pre machining operation 59

4.1 Graph for surface roughness Vs machining time for Bacteriostatic Emulsifiable

cutting fluids + Palm Oil 66

4.2 Graph for surface roughness Vs cutting speed for Bacteriostatic Emulsifiable

cutting fluids + Palm Oil 67

4.3 Graph for surface roughness Vs machining time for Bacteriostatic Emulsifiable

(Razif, 2007) 70

4.4 Graph for surface roughness Vs cutting speed for Bacteriostatic Emulsifiable

(Razif, 2007) 71

4.5 (a) Surface texture of mild steel before turning process for speed 185 rpm 72 4.5(b) Surface texture for cutting speed 185 rpm 72 4.6 (a) Surface texture of mild steel before turning process for speed 340 rpm 73 4.6 (b) Surface texture for cutting speed 340 rpm 73 4.7 (a) Surface texture of mild steel before turning process for speed 425 rpm 74 4.7 (b) Surface texture for cutting speed 425 rpm 74 4.8 (a) Surface texture of mild steel before turning process for speed 625 rpm 75 4.8 (b) Surface texture for cutting speed 625 rpm 75 4.9 Comparison graph for cutting speed 185 rpm 77 4.10 Comparison graph for cutting speed 340 rpm 78 4.11 Comparison graph for cutting speed 425 rpm 79 4.12 Comparison graph for cutting speed 625 rpm 80

4.13 Comparison graph for 5 minutes 81

4.14 Comparison graph for 7.5 minutes 82

4.15 Comparison graph for 10 minutes 83

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LIST OF TABLES

2.1 Suitable types of cutting fluids depend to materials machining operation 18 2.2 ISO-Recommended Roughness Values and Grade Numbers for the specification

of surface roughness 39

3.1 Experiment design 58

4.1 Surface roughness experiment data using Bacteriostatic Emulsifiable Cutting

Fluids mixed with palm oil 63

4.2 Specific result of surface roughness value obtained from Bacteriostatic Emulsifiable cutting fluids mixed with palm oil experiment 65 4.3 Specific result of surface roughness value obtained from Bacteriostatic

Emulsifiable experiment (Razif, 2007) 69

4.4 Surface roughness experiment data using Bacteristatic Emulsifiable (Razif, 2007) 68

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LIST OF ABBREVIATIONS, SIGNS, AND SYMBOLS

AISI - American Iron and Steel Institute BUE - built up edge

C - Carbon

CLA - centre line average

EP - extreme pressure

EPA - Environment Protection Agency

Eq - equation

Fe - Ferum

FKP - Fakulti Kejuruteraan Pembuatan HSS - high speed steel

in - inch

ipr - inch per revolution

ISO - International Organization for Standardization KeV - kilo electron volt

kPa - kilo Pascal

mm - millimetre (metric unit) psi - per square inch

PSM - Projek Sarjana Muda

Ra - arithmetic mean value (roughness average) Rpm - revolution per minute

Rq - root mean square average SEM - scanning electron microscopy sfpm - square feet per minute

UTeM - Universiti Teknikal Malaysia Melaka

µm - micrometer (1 millionth of a meter) (metric unit) µin - microinch (1 millionth of an inch)

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CHAPTER 1 INTRODUCTION

1.1 Introduction

Generally, cutting fluids usage in machining are vital because they help in dissipating heat generated by metal cutting process, reduce friction and wear, thus improving tool life and the surface finish of the workpiece, reduce forces and energy consumption, flush away the chips from the cutting zone. It also prevents the chips from interfering with the cutting process, particularly in operations such as drilling and tapping and protects the machined surface from environmental corrosion.

However, the cutting fluid itself are environmentally unfriendly, costly, and potentially toxic. The recent shift to dry cutting has not completely solved the problem. Dry cutting increases energy costs, increases per part costs, and requires a capital investment that is too large for most machine shops. This approach is a cost-effective or practical way to eliminate the use of environmentally unfriendly cutting fluids. They either require oils of questionable effectiveness or flow, high-pressure systems that would be costly and difficult to implement in a production environment.

Due to the many problems regarding to the healthy and the environmental issues, the vegetable oil such as the soybean oil and palm oil are finding their way into lubricants for industrial applications. It is seems that it is the suitable replacements of the conventional coolants. These oils such as palm oil, indeed offer significant environmental benefits with respect to resource renewability, biodegradability, as

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Many techniques can be used to determine the performance of coolant and its effect to environment, human and productivity. We choose to compare the performance between only environmental friendly coolant and environmental friendly coolant mixed with palm oil on the value of the surface roughness obtained on the machined specimen and hopefully we can get the answer to the problems occurred in cutting fluids issue.

This paper will reveal the effects of both coolants tested based on the value of surface roughness using turning process. Details of related topics are discussed and presented also a result of the experiment that may provide a solution to the problems stated.

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1.2 Problem Statement

Regarding to this project, we found that a few problems occurred in the process of selecting the right cutting fluid to be used. Therefore, solutions need to be found to solve the problems below:

a. Very little study on the development of palm oil into metalworking fluids lead to an unclear status of palm oil usage in machining operation.

b. Vegetable oil and soybean oil have been tested in machining and good result obtained. The cost of making those oils is quite expensive. In reducing the cost of production, cheaper natural source need to be develop.

c. The chemical based coolants used nowadays are harmful to the operator and environment compared to the environmental friendly coolants. The performances between those oils are similar. Since the issues of environment pollution and hazard to workers rise up, there is still less action in developing safe and efficient metalworking fluids.

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1.3 Objectives

The objectives of this research are:

a. To carry out experiment using oil based coolant and combination of oil based

coolant with palm oil in turning operation and evaluate the surface finish performance by analyzing the surface roughness of the specimen machined.

a. To compare and identify the best coolant between the oil-based coolant and

the combination of oil-based coolant with palm oil in the aspect of surface finish

b. To determine whether palm oil is suitable for the machining operation and

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1.4 Project Scope

Basically, this project conducted to compare the performance between oil based coolant and combination of oil based coolant with palm oil in turning operation and the performance is evaluated from the surface finish of the specimen machined. High speed steel (HSS) is used as a cutting tool and the material for turning operation is mild steel (AISI 1045). The process is performed under different parameters such as feed rate, cutting speed, depth of cut and cutting time. This study will be focusing on the surface finish obtained from the machining using two different types of coolants performance. Samples from the machining operation will be analyzed using surface roughness tester and metallurgy microscope. The value of surface roughness from the specimens will be recorded for making comparison for the both cutting fluids used. Discussions are made under the result obtain and the most suitable coolant to be used will be stated in conclusion made.

1.5 Limitation of Scope

This study is carried out only to analyze the cutting fluids performance on the specimen’s surface. Although parameters in machining and other factors also play an important role in obtaining good surface finish, the discussion will be made only on the role played by cutting fluids used by evaluating the specimens surface roughness value. Also, the surface textures gained after being machined only being observed its character.

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CHAPTER 2 LITERITURE REVIEW

2.1 Introduction

In this chapter, brief explanations about related topics on this research are revealed. This chapter will discuss about cutting fluids and criteria which are related to cutting fluids fundamentals which is suitable to be a revision for this study. Also being discussed in this chapter is about lathe machine and its operation such as turning and also about surface metrology. All of the fundamentals about related topics are taken from previous studies from journals, books and articles.

2.2 Introduction to Cutting Fluids

Cutting fluids are widely used throughout industry in many machining operations such as milling, grinding, boring, and turning. Large machining facilities use central fluid systems with capacities as high as 760 000 liters, and it is estimated that over 380 million liters of metalworking fluids are used each year (Gunther & Sutherland, 1999).

Cutting fluids are used to optimize a lot of machining operation such as turning, drilling boring, grinding and milling. The main purpose of using cutting fluid is to reduce cutting zone temperature in order to increase tool life and also to gain good surface finish (Diniz & Micaroni, 2007)

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Depending on the type of machining operation, the cutting fluid needed may be a coolant, a lubricant, or both. The effectiveness of cutting fluids depends on a number of factors, such as the type of machining operation, tool and workpiece materials, cutting speed, and the method of application. Water is an excellent coolant and can reduce effectively the high temperatures developed in the cutting zone. However, water is not an effective lubricant; hence it does not reduce friction. Furthermore, it causes the rusting of workpieces and machine-tool components. On the other hand, as we have seen, effective lubrication is an important factor in machining operations (Kalpakjian & Schmid, 2001).

The need for a cutting fluid depends on the severity of the particular machining operation, which may be defined as the level of temperatures and forces encountered, the tendency for built-up edge (BUE) formation, the ease with which chips produced can be removed from the cutting zone, and how effectively the fluids can be applied to the proper region at the tool-chip interface. The relative severities of specific ma-chining processes in increasing order of severity are: sawing, turning, milling, drilling, gear cutting, thread cutting, tapping, and internal broaching (Kalpakjian & Schmid, 2001).

Cutting fluids can be found in many types in nowadays market, the most common of which can be broadly categorized as cutting oils or water miscible fluids. Water miscible fluids, including soluble oils, synthetics and semi synthetics are now used in approximately 80 to 90% of all application. Although straight cutting oils are less popular than they were in the past, they are still the fluid of choice for certain metalworking applications (Anon.,University of Northern Iowa, 2003).

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1.2 Problem Statement

Regarding to this project, we found that a few problems occurred in the process of selecting the right cutting fluid to be used. Therefore, solutions need to be found to solve the problems below:

a. Very little study on the development of palm oil into metalworking fluids lead to an unclear status of palm oil usage in machining operation.

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4 1.3 Objectives

The objectives of this research are:

a. To carry out experiment using oil based coolant and combination of oil based coolant with palm oil in turning operation and evaluate the surface finish performance by analyzing the surface roughness of the specimen machined.

a. To compare and identify the best coolant between the oil-based coolant and the combination of oil-based coolant with palm oil in the aspect of surface finish