2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable based oil for machining
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The document discusses the use of vegetable oil-based minimum quantity lubrication (MQL) versus conventional mineral oil during machining processes. It highlights the environmental and technical advantages of vegetable oils, such as higher lubricity and lower emissions, while presenting experimental results on their effectiveness in machining mild steel and austenitic stainless steel. The study indicates that while vegetable oil MQL has certain benefits, it struggles with heat absorption in the cutting zone compared to mineral oils.
![Experimental Results
Of Chip curl Radius
Results
The novel coconut oil based MWF under MQL
was failed to absorb heat from cutting zone when
compared mineral oil.
0.000
0.200
0.400
0.600
0.800
1.000
1.200
1.400
1.600
1.800
0.000 20.000 40.000 60.000 80.000 100.000 120.000
ChipCurlRadius(mm)
Cutting Speed (m/min)
1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate (Mild
Steel)
Emulsion
Soluble
0.000
1.000
2.000
3.000
4.000
5.000
6.000
0.000 20.000 40.000 60.000 80.000 100.000 120.000
ChipCurlRadius(mm)
Cutting Speed (m/min)
1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate
(AISI 304)
Emulsion
Soluble
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 𝑜𝑓 𝑐ℎ𝑖𝑝𝑠 ∝
1
𝐶ℎ𝑖𝑝 𝑐𝑢𝑟𝑙 𝑟𝑎𝑑𝑖𝑢𝑠
[26]
Page 13 of 20](https://image.slidesharecdn.com/2ndprogresspresentationgr-19-181013044230/85/2nd-progress-presentation-on-Minimum-Quantity-Lubrication-MQL-with-vegitable-based-oil-for-machining-13-320.jpg)
![References
[1] I. A. C. Y. N. Sunday Albert Lawal, "A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant," Journal
of Cleaner Production, vol. 41, pp. 210-221, 2013.
[2] N. M. Y. H. I. Z. A. A. S. R. R. SAFIAN SHARIF, "FEASIBILITY STUDY OF USING VEGETABLE OIL AS A CUTTING LUBRICANT THROUGH THE USE OF MINIMUM QUANTITY
LUBRICATION DURING MACHINING," Malaysia, 2009.
[3] I. P. O. J. E. S. C. A. E. Ugochukwu C. Okonkwo, "Comparative analysis of aluminium surface roughness in end-milling under dry and minimum quantity lubrication (MQL) conditions," EDP
Sciences, Kwara, Nigeria, 2016.
[4] S. D. N. D. S. Ali, "EFFECT OF MINIMUM QUANTITY LUBRICATION (MQL) ON CUTTING PERFORMANCE IN TURNING MEDIUM CARBON STEEL BY UNCOATED CARBIDE INSERT AT
DIFFERENT SPEED-FEED COMBINATIONS," Advances in Production Engineering & Management, vol. 6, no. 3, pp. 185-196, 2011.
[5] G. I. P. P. H. M. C. M. H. K. C. Wickramasinghe, "Formulation and performance evaluation of a novel coconut oil-based metal working fluid," Materials and Manufacturing Processes, vol. 32, no.
9, pp. 1026-1033, 2017.
[6] D. Lohar and C. Nanavaty, "Performance Evaluation of Minimum Quantity Lubrication (MQL) using CBN Tool during Hard Turning of AISI 4340 and its Comparison with Dry and Wet Turning,"
vol. 03, 03 September 2013.
[7] H. B. O. C. Ojmertz, "Wear on SiC-Whiskers Reinforced Ceramic Inserts When Cutting Inconel With Waterjet Assistance," Tribology Transactions, vol. 3, no. 42, pp. 471-478, 1999.
[8] J. B. B. C. Evans, "Cryogenic Diamond Turning of Stainless Steel," CIRP Annals - Manufacturing Technology, vol. 1, no. 40, pp. 571-575, 1991.
[9] U. S. K. B. G. S. Lathkar, "Clean metal cutting process using solid lubricants," in 19th AIMTDR Conference, Madras, India, 2000.
[10] V. L. Godlevskiy, "Water steam lubrication during machining," Tribology, vol. 6, no. 162, pp. 890-901, 1998.
[11] J. W. A. Machado, "The effect of extremely low lubricant volumes in machining," Wear, Vols. 1-2, no. 210, pp. 76-82, 1997.
[12] S. Ali, N. Dhar and Dey S.K, "EFFECT OF MINIMUM QUANTITY LUBRICATION (MQL)," 2011.
[13] A. Jayal and A. Balaji, "Effects of cutting fluid application on tool wear in machining.," interactions with tool coatings and tool surface features., 2009.
[14] R. Y. U. R. T. S. C. A. H. A.-M. H. A. Hamid, "Synthesis of palm oil-based trimethylolpropane ester as potential biolubricant: Chemical kinetics modeling," Chemical Engineering Journal, pp. 532-
540, 2012.
Page 18 of 20](https://image.slidesharecdn.com/2ndprogresspresentationgr-19-181013044230/85/2nd-progress-presentation-on-Minimum-Quantity-Lubrication-MQL-with-vegitable-based-oil-for-machining-18-320.jpg)
![[15] I. Gawrilow, "Palm Oil Usage In Lubricant,3rd Global Oils and Fats Business," 2003.
[16] I. Gawrilow, "Vegetable oil usage in lubricants," OLEOCHEMICALS, vol. 15, no. 11, pp. 702-705, 2004.
[17] T. WAKABAYASHI, "Trobological action and cutting performance of lubricant ester in MQL machining," in 4th Malaysia-Japan Tribology Symposium, Kuala Lumpur, Malaysia, 2016.
[18] S. P. S. ,. D. P. G. S. V. K. D. C. Rakesh Somashekaraiah, "Eco-Friendly, Non-Toxic Cutting Fluid for Sustainable Manufacturing and Machining Processes," Tribology Online, vol. 5, no. 11,
pp. 556-567, 2016.
[19] K. T. A. F. M. A. I. Nurul Adlina M.J., "A Study of Surface Roughness & Surface Integrity in Drilling Process Using Various Vegetable – Oil Based Lubricants In Minimum Quantity
Lubrication," Australian Journal of Basic and Applied Sciences, vol. 15, no. 8, pp. 191-197, 2014.
[20] P. D. S. Sharif and P. D. N. M. Yusof, "FEASIBILITY STUDY OF USING VEGETABLE OIL AS A CUTTING LUBRICANT THROUGH THE USE OF MINIMUM QUANTITY LUBRICATION
DURING MACHINING.," 2009.
[21] Irfan Ucun, Kubilay Aslantas and Fevzi Bedir, "The effect of minimum quantity lubrication and cryogenic pre-cooling on cutting performance in the micro milling of Inconel 718," in SAGE
Publications., 2014.
[22] A. V. M. H. F. J. Soroush Masoudi, "Experimental investigation into the effects of nozzle position, workpiece hardness, and tool type in MQL turning of AISI 1045 steel," Materials and
Manufacturing Processes, pp. 1-8, 2017.
[23] S. K. Shreyash Mukte, "A Review Paper on Minimum Quantity Lubrication," International Journal for Scientific Research & Development, vol. 4, no. 11, pp. 688-689, 2017.
[24] "Minimum quantity lubrication," [Online]. Available: https//www.slideshare.net. [Accessed 25 February 2018].
[25] A. M. P. A. C. Y.Iskandar, "Flow visualization and characterization for optimized MQL machining of composites," Manufacturing technology, vol. 63, no. 1, pp. 77-80, 2014.
[26] Y. R. Z. Li, "A Study of Chip Breaking Limits in Machining," Machining Sciences and Technology, vol. 3, no. 1, pp. 25-48, 1999.
[27] M. R. M. K. K. N. H. Razak, "A REVIEW OF MINIMUM QUANTITY LUBRICANT ON MACHINING PERFORMANCE," in National Conference in Mechanical Engineering Research and
Postgraduate Students, Kuantan, Pahang, Malaysia, 2010.
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2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable based oil for machining
- 1. Vegetable Oil Based Minimum Quantity Lubrication (MQL) During Machining Department of Mechanical and Manufacturing Engineering – University of Ruhuna
- 2. We are UGP2018 - 19 Dr. G. Indika P. Perera Advisor Mr. K. C. Wickramasingha Co - Advisor Mr. N. Sarmilan Member 01 Ms. W. L. R. Fernando Member 02
- 3. Outline • 01 Introduction • 02 Methodology • 03 Flow Rate Analysis • 05 Results • 04 Current Progress • 06 Future Works • 07 Time Plan and References Page 03 of 20
- 4. Introduction Micro lubrication or near dry lubrication, is a lubrication technique of applying fine mist of oil instead a flood of MWF. The typical flow rate of MWF is in between 50-500ml/hour. Minimum Quantity Lubrication(MQL) Gives more advantages than petroleum oils such as high lubricity, high load carrying capacity, low volatility, low emission of hydrocarbons, good thermal properties, good solvency and higher fire resistance. Vegetable oil Based MWF Causes to create various environmental and technical problems such as water pollution and soil contamination during disposal, environmental infection caused by chemical disassociation of MWF at high cutting temperatures and biological issues to operators. Mineral oil Based MWF A technique of applying a steady flood of MWF to cutting tool-workpiece interface. It had shown inefficient performances due to disability of reach the real cutting area with gradually increasing feed rates and cutting velocities. Flood Cooling Page 04 of 20
- 5. Methodology In the experimental stage, the Mild Steel and AISI 304 Austenitic stainless steel were machined under lathe turning operation. As coolants, both novel vegetable oil based MWF and conventional mineral oil based MWF under Minimum Quantity Lubrication (MQL) were applied. from overall project was completed.75% Around The machining performances of machined regions in terms of surface roughness and chip formation were evaluated. 90% Initiating the project and literature review 100% Design the experimental setup 100% Establish the experimental setup 15% Final report and research paper work 55% Conduct the experiments and data analysis Page 05 of 20
- 6. Flow Rate Analysis Table 2: Flow rate of MWFs at 3 bar pressure Table 1: Flow rates of water under different air pressures and valve positions for 500 ml of water Metal Working Fluid Flow rate (ml/s) Mineral oil based MWF 0.177 Vegetable oil based MWF 0.186 Pressure (bar) Ball valve opening % (Compres sed air) Ball valve opening % (Water) Time (s) Flow rate (ml/s) 4 100 10 733 0.682 4 100 5 2360 0.212 3 50 5 2520 0.198 Page 06 of 20
- 7. Current Progress 1 2 3 4 5 67 8 9 10 11 12 MS SS TA MS SS TAMS SS TA MS SS TA Veg MinVeg MQL Flood Dry Materials MS – Mild Steel SS – Stainless Steel TA – Titanium Alloy MWFs Veg – Newly Developed Vegetable oil based MWF Min – Mineral oil based MWF Cutting Parameters Feed rate - 0.05mm/rev Depth of cut - 1.0mm Spindle speeds – 45rpm, 585rpm, 900rpm Page 07 of 20
- 8. Current Progress Page 08 of 20 We Have a Video Clip of Experiments for you
- 9. Why the difference…? Experimental Results Of Surface Roughness Results The novel coconut oil based MWF under MQL is a better cooling technique for Mild Steel than Austenitic stainless steel to obtain the superior surface finish. 0.000 0.500 1.000 1.500 2.000 2.500 3.000 3.500 0.000 20.000 40.000 60.000 80.000 100.000 120.000 SurfaceRouhgness(µm) Cutting Speed (m/min) 1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate (Mild Steel) Emulsion Soluble 0.000 0.500 1.000 1.500 2.000 2.500 3.000 0.000 20.000 40.000 60.000 80.000 100.000 120.000 SurfaceRoughness(µm) Cutting Speed (m/min) 1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate (AISI 304) Emulsion Soluble Page 09 of 20
- 10. Chip Morphology| Deviation of external appearance of the chips with increasing spindle speed Chip color Low values of chip curl radius causes to higher tensile strain of the chip. It leads to higher value of energy utilization and heat propagation at cutting region Chip curl radius Short chips show the better machining performances than long chips Chip length An ISO recommendation Gives the bench mark for future studies Favorability A B C Different types of chips formed during turning operation of AISI 304 Stainless Steel by using vegetable oil based MWF under MQL condition ((A) 45rpm (B) 585rpm (C) 900rpm) Results
- 11. Results Chip Morphology| Mild Steel – Soluble oil Mild Steel – Emulsion Spindle Speed (rpm) Chip Curl radius (mm) Chip length (mm) Chip Color Favorability 45 1.332 10.780 Metallic Favorable 585 1.310 50.900 Metallic Favorable 900 1.216 54.330 Metallic Favorable Spindle Speed (rpm) Chip Curl radius (mm) Chip length (mm) Chip Color Favorability 45 1.707 Long Metallic Unfavorable 585 1.237 56.740 Metallic Favorable 900 0.903 54.930 Metallic Favorable Page 11 of 20
- 12. Results Chip Morphology| Spindle Speed (rpm) Chip Curl radius (mm) Chip length (mm) Chip Color Favorability 45 1.149 Long Metallic Unfavorable 585 4.525 Long Metallic Unfavorable 900 5.364 Long Golden Unfavorable AISI 304– Emulsion Spindle Speed (rpm) Chip Curl radius (mm) Chip length (mm) Chip Color Favorability 45 0.822 Long Metallic Unfavorable 585 2.392 32.49 Metallic Favorable 900 2.950 83.06 Metallic Favorable AISI 304– Soluble oil Page 12 of 20
- 13. Experimental Results Of Chip curl Radius Results The novel coconut oil based MWF under MQL was failed to absorb heat from cutting zone when compared mineral oil. 0.000 0.200 0.400 0.600 0.800 1.000 1.200 1.400 1.600 1.800 0.000 20.000 40.000 60.000 80.000 100.000 120.000 ChipCurlRadius(mm) Cutting Speed (m/min) 1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate (Mild Steel) Emulsion Soluble 0.000 1.000 2.000 3.000 4.000 5.000 6.000 0.000 20.000 40.000 60.000 80.000 100.000 120.000 ChipCurlRadius(mm) Cutting Speed (m/min) 1.0 mm Depth of Cut @ 0.05 mm/rev of Feed Rate (AISI 304) Emulsion Soluble 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 𝑜𝑓 𝑐ℎ𝑖𝑝𝑠 ∝ 1 𝐶ℎ𝑖𝑝 𝑐𝑢𝑟𝑙 𝑟𝑎𝑑𝑖𝑢𝑠 [26] Page 13 of 20
- 14. Future works Identify and compare the impact of MWF on tool wear Evaluation of tool wear 03 Machining of Mild Steel and AISI 304 under MQL condition by increasing the flow rate of MWF. Identification of Impact of Flow rate 02 Machining of Mild Steel and AISI 304 under flood and dry condition. Identification of impact of lubrication Techniques 01 Page 14 of 20
- 15. Plan Duration % Complete % Complete (beyond plan) Actual Start Actual (beyond plan) ACTIVITY SUB ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 1.Initiating project 1.1 Topic selection 1 1 1 1 100% 1.2 Define scope 1 2 1 2 100% 2.Literature Review 1 14 1 15 90% 3.Design Experimental setup 3.1 Conceptual design 5 1 5 1 100% 3.2 Selection of the setup 6 1 6 1 100% 3.3 Modelling of the setup 7 2 7 2 100% 3.4 Finalize our Design 9 1 9 1 100% 3.5 Fabrication 10 2 10 3 100% 4.Establish Testing Setup 4.1 Constructing Componants 12 3 12 4 100% 4.2 System Installation 13 3 13 3 100% 4.3 System commissioning 15 2 15 3 100% 5. Experiments 5.1 Surface Roughness 17 2 17 0 50% 5.2 Tool Wear 17 2 17 0 0% 5.4 Chip formation 17 2 17 0 50% 6.Data Analysis 19 1 0 0 0% 7. Conclusion 20 1 0 0 0% 8. Report writing 21 1 0 0 0% 9. Research Paper work 22 7 0 0 0% Time Plan PERIODS (WEEKS)PLAN START PLAN DURATION ACTUAL START ACTUAL DURATION PERCENT COMPLETE Page 15 of 20
- 16. We were there In SAMR’18 Colombo, Sri Lanka The South Asia Conference on Multidisciplinary Research 2018 (SAMR’18), organized by The International Research and Development Institution (TIRDI), was held on 05th October 2018. A premier knowledge building event, provided unequalled networking opportunities and presenter friendly academic environment. Page 16 of 20
- 17. Colombo, Sri Lanka The South Asia Conference on Multidisciplinary Research - 2018 Page 17 of 20
- 18. References [1] I. A. C. Y. N. Sunday Albert Lawal, "A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant," Journal of Cleaner Production, vol. 41, pp. 210-221, 2013. [2] N. M. Y. H. I. Z. A. A. S. R. R. SAFIAN SHARIF, "FEASIBILITY STUDY OF USING VEGETABLE OIL AS A CUTTING LUBRICANT THROUGH THE USE OF MINIMUM QUANTITY LUBRICATION DURING MACHINING," Malaysia, 2009. [3] I. P. O. J. E. S. C. A. E. Ugochukwu C. Okonkwo, "Comparative analysis of aluminium surface roughness in end-milling under dry and minimum quantity lubrication (MQL) conditions," EDP Sciences, Kwara, Nigeria, 2016. [4] S. D. N. D. S. Ali, "EFFECT OF MINIMUM QUANTITY LUBRICATION (MQL) ON CUTTING PERFORMANCE IN TURNING MEDIUM CARBON STEEL BY UNCOATED CARBIDE INSERT AT DIFFERENT SPEED-FEED COMBINATIONS," Advances in Production Engineering & Management, vol. 6, no. 3, pp. 185-196, 2011. [5] G. I. P. P. H. M. C. M. H. K. C. Wickramasinghe, "Formulation and performance evaluation of a novel coconut oil-based metal working fluid," Materials and Manufacturing Processes, vol. 32, no. 9, pp. 1026-1033, 2017. [6] D. Lohar and C. Nanavaty, "Performance Evaluation of Minimum Quantity Lubrication (MQL) using CBN Tool during Hard Turning of AISI 4340 and its Comparison with Dry and Wet Turning," vol. 03, 03 September 2013. [7] H. B. O. C. Ojmertz, "Wear on SiC-Whiskers Reinforced Ceramic Inserts When Cutting Inconel With Waterjet Assistance," Tribology Transactions, vol. 3, no. 42, pp. 471-478, 1999. [8] J. B. B. C. Evans, "Cryogenic Diamond Turning of Stainless Steel," CIRP Annals - Manufacturing Technology, vol. 1, no. 40, pp. 571-575, 1991. [9] U. S. K. B. G. S. Lathkar, "Clean metal cutting process using solid lubricants," in 19th AIMTDR Conference, Madras, India, 2000. [10] V. L. Godlevskiy, "Water steam lubrication during machining," Tribology, vol. 6, no. 162, pp. 890-901, 1998. [11] J. W. A. Machado, "The effect of extremely low lubricant volumes in machining," Wear, Vols. 1-2, no. 210, pp. 76-82, 1997. [12] S. Ali, N. Dhar and Dey S.K, "EFFECT OF MINIMUM QUANTITY LUBRICATION (MQL)," 2011. [13] A. Jayal and A. Balaji, "Effects of cutting fluid application on tool wear in machining.," interactions with tool coatings and tool surface features., 2009. [14] R. Y. U. R. T. S. C. A. H. A.-M. H. A. Hamid, "Synthesis of palm oil-based trimethylolpropane ester as potential biolubricant: Chemical kinetics modeling," Chemical Engineering Journal, pp. 532- 540, 2012. Page 18 of 20
- 19. [15] I. Gawrilow, "Palm Oil Usage In Lubricant,3rd Global Oils and Fats Business," 2003. [16] I. Gawrilow, "Vegetable oil usage in lubricants," OLEOCHEMICALS, vol. 15, no. 11, pp. 702-705, 2004. [17] T. WAKABAYASHI, "Trobological action and cutting performance of lubricant ester in MQL machining," in 4th Malaysia-Japan Tribology Symposium, Kuala Lumpur, Malaysia, 2016. [18] S. P. S. ,. D. P. G. S. V. K. D. C. Rakesh Somashekaraiah, "Eco-Friendly, Non-Toxic Cutting Fluid for Sustainable Manufacturing and Machining Processes," Tribology Online, vol. 5, no. 11, pp. 556-567, 2016. [19] K. T. A. F. M. A. I. Nurul Adlina M.J., "A Study of Surface Roughness & Surface Integrity in Drilling Process Using Various Vegetable – Oil Based Lubricants In Minimum Quantity Lubrication," Australian Journal of Basic and Applied Sciences, vol. 15, no. 8, pp. 191-197, 2014. [20] P. D. S. Sharif and P. D. N. M. Yusof, "FEASIBILITY STUDY OF USING VEGETABLE OIL AS A CUTTING LUBRICANT THROUGH THE USE OF MINIMUM QUANTITY LUBRICATION DURING MACHINING.," 2009. [21] Irfan Ucun, Kubilay Aslantas and Fevzi Bedir, "The effect of minimum quantity lubrication and cryogenic pre-cooling on cutting performance in the micro milling of Inconel 718," in SAGE Publications., 2014. [22] A. V. M. H. F. J. Soroush Masoudi, "Experimental investigation into the effects of nozzle position, workpiece hardness, and tool type in MQL turning of AISI 1045 steel," Materials and Manufacturing Processes, pp. 1-8, 2017. [23] S. K. Shreyash Mukte, "A Review Paper on Minimum Quantity Lubrication," International Journal for Scientific Research & Development, vol. 4, no. 11, pp. 688-689, 2017. [24] "Minimum quantity lubrication," [Online]. Available: https//www.slideshare.net. [Accessed 25 February 2018]. [25] A. M. P. A. C. Y.Iskandar, "Flow visualization and characterization for optimized MQL machining of composites," Manufacturing technology, vol. 63, no. 1, pp. 77-80, 2014. [26] Y. R. Z. Li, "A Study of Chip Breaking Limits in Machining," Machining Sciences and Technology, vol. 3, no. 1, pp. 25-48, 1999. [27] M. R. M. K. K. N. H. Razak, "A REVIEW OF MINIMUM QUANTITY LUBRICANT ON MACHINING PERFORMANCE," in National Conference in Mechanical Engineering Research and Postgraduate Students, Kuantan, Pahang, Malaysia, 2010. Page 19 of 20