TABLE OF CONTENTS
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 2.3.4
Synthetics 10
v
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
2.11.5 Turning
Parameters 33
vi
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 3.8.4
Feed Rate 5
vii
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
