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Alternative Cutting Fluids for Metal Cutting Operations
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 5 (2018) 7758–7764
www.materialstoday.com/proceeding s
IMME17
Alternative Cutting Fluids for Metal Cutting Operations Lokesh Srinivasan1 S, Vimalathithan R, Manojkumar M V Sri Sairam Engineering College, West Tambaram, Chennai-600044,India.
Abstract In machining operation, the life of the tool is important as lot of heat energy is generated during machining process. Due to the heat developed the surface finish, dimensional accuracy and life of the material, which is machined is affected .There are different approaches under study to find an alternative. Thus neem oil and water melon seed oil was studied and made as an alternative as cutting fluids in order to improve the life of the tool, improve surface finish in work piece, prevent corrosion in a steel, maintaining dimensional accuracy. Rather than coating the tool to machine high strength alloys, it found to be a simple alternative. Physiochemical properties such as viscosity, flash point, pour point, specific gravity were studied. Specific gravity of Neem seed oil was 0.9304 and Water Melon seed oil was 0.9324. The flash point for Neem seed oil was obtained as 1750C, Water melon seed oil 130°C. Based on the property results machining operation is carried out at different spindle speeds with various ratio of both the oils and water. The best results were obtained with more absorption of heat energy and temperature was reduced than the current machining process, which will be explained briefly in the paper. All the oils – water emulsion ratios were effective as coolants and comparable to the petroleum oils. As in current machining process petroleum oil is used as a coolant but the availability and cost of the petroleum oils is critical. Thus there is a need for an alternative source of oil which could reduce the cost, increase its availability, prevents environmental pollution and should be a renewable one. Neem oil and water melon oil satisfies those conditions and it is not prone to workers as petroleum oil results is skin irritation and imbalance in health. In the current situation many industries are in need for alternative coolants to make the tools better usage for longer time period so it adds value to the work piece quantitatively and qualitatively and it helps in economic aspect of country too. © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering (IMME17). Keywords: Physiochemical properties; Neem oil;Water Melon Oil;Machining;Renewable.
1. Introduction The current market trend in renewable lubricant technology is making its stand in many industries and manufacturing sectors. It is driven by global warming, renewable resources, ethical corporate policies, cost of oil and government strategies to encourage vegetable oils in use. The researchers are making their interest in metal working fluids (MWF) which is termed as vegetable oils. People are interested in the conserving of the environment,
* Corresponding author. E-mail address: [email protected]
2214-7853 © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering (IMME17).
Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764
7759
health and safety of employees are given special care and enhancing the government economy and making the societies independent on oil [11]. Increasing demand for eco- friendly lubricant has led researchers to choose vegetable oils as the better alternative [15]. Modern metal working fluids are quite effective if environmental conservation is not included. Cost reductions are possible only through the performance increase in the areas which include life of the tool, surface finish of the machined product and enhanced cutting process speed and feeds [8]. However, when compared to conventional oil, vegetable oil can improve cutting performance, enhance tool life and surface texture is improved. Many new coolants have been developed to meet the needs of new materials, new cutting tools, new coatings on cutting tools. The goals of machining operations are to increase productivity in manufacturing sector and maintain accuracy at reduced cost. This is achieved by machining at the practical speed while maintaining practical tool life, reducing wear and producing parts with the desired surface finish or quality. During machining at practical speeds the work piece and the tool has the adverse effects based on its wear, surface finish and heat generated. Thus it is the challenging task to replace vegetable oils such as neem oil and water melon oil at this practical speeds and generate the optimized good results. 1.1 Experimental Methodology About 3 kg of neem seed samples are brought from the market. The seeds were sun dried in order to separate seed coat from the seed. Winnowing was carried out to separate and obtain clean seeds .The clean seeds were poured in Mortar and pestle to crush the seeds and obtain it in the paste like form. The neem paste is taken in the bowl and mixed with 300 ml of water. The proper mixing is done and then Neem paste is placed in the oven and the temperature was set in the range of 1200 C to 140 0 C and the heating was carried out for certain time period of 20 minutes. This temperature range is to increase the flow of oil during high pressure. In order to eliminate the complete oil from the seed paste was transformed to sieving cloth of very fine grade. Then the edges of sieving cloth were tied and the sieving cloth with neem paste was kept along with the mechanical press. Jack was used to apply the pressure continuously so that the oil is continuously squeezed out of the paste. The resulted neem oil is further processed for transesterification process in order to remove the fatty acids from it and to eliminate the nasty smell from it. Transesterification is the reaction between fat or oil with alcohol which result in glycerol and esters. This process was carried out until the complete oil is extracted from the paste and the oil was collected in the flask. The same procedure was repeated to extract the oil from water melon seeds. 1.2 Oil Properties The properties tested were given in Table 1 and compared with other results and it agreed with other results of researchers. Kinematic Viscosity of neem oil obtained at 120 0C as 7.08 which comparable with reference [1] but differ with [3]. Kinematic viscosity was calculated using ASTM D445. Water Melon had viscosity of 7.52. All results agreed with available literature on viscosities of oils. Viscosity plays a significant role on ability of oil to flow and also to remain stable at particular temperatures for a period of time. The pour point was obtained and it shows for all the oils, it can be poured relatively easily and hence the flow was not a problem. Neem had the least pour point of +8°C while Water Melon had the best result at -8°C. Pour point was calculated using ASTM D97. The flash point of neem and water melon was calculated using pensky-martens closed cup tester ASTM D93. The flash point of neem oil and water melon oil was 160 0 C and 120 0 C respectively. The pH of all the oils shows some level of acidity Neem oil had a pH of 6.12 and the pH of Water Melon was found to be 6.56. The low pH values support use of oils and it prevents the worker from skin irritation. Also, the tool and work piece are not corroded due to its pH value. However pH of 4.75- 9.75 is acceptable to the skin. This values are tested using pH meter. Sulphur content in oil plays a vital role too. Neem oil with 0.0293 %Sulphur which differs from 0.48 % from reference [3] and water melon %Sulphur was nil. The Sulphur content was very low in both the oils and it is tested using Horbia apparatus model SLFA2800 Sulphur in oil analyzer by X-RAY machine. Sulphur is used as an additive in lubricants and cutting fluids [7]. Since % Sulphur was low in oil samples, the Sulphur content can be added with few percentage to improve its function. Specific gravity is tested using ASTM D94 standard test procedure. Relative density result of water melon oil used was 0.9322. This compared closer to the value obtained in the reference [12]. Neem oil had relative density of 0.9302 which comparable to reference [3].
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1.3 Machining Process The work piece is fixed in the three jaw self-centering chuck of a lathe machine and properly tightened using chuck key. A high speed steel (HSS) is mounted on the lathe tool post. The tool is fixed with proper clearance and rack angle. The thermocouple wire (K TYPE) was set so that it just touched the cutting zone of the work piece. The thermocouple was then connected to digital electronic temperature indicating regulator of range (-200 0 C to 1350 0 C). This is the temperature at the cutting zone. Dry machining is carried out on a single work piece made up of mild steel of spindle speeds of 250 rpm. Readings were repeated so that average temperature was obtained. One vegetable oil (Neem oil) being tested was poured into water bottle used as the applicator and machining operation was carried out with oil applied from water bottle at speed of 250rpm. Machining operation was repeated with the Neem oil. The oil was then mixed with water at a 50% to 50% ratio and used to machine another work piece using the same parameters stated above and equally taking three readings. The Neem oil was again mixed with water at a ratio of 25% Neem oil to 75% water and the same procedure was repeated in carrying out the machining and recording. This machining process was carried out to get the results of temperature which get reduced due to the cooling property of the neem oil and water melon oil. 1.4 Table Results Table 1. Results of physiochemical analysis of two vegetable oils. Properties
Neem Oil
Water Melon oil
Specific Gravity
0.9302
0.9322
Pour Point 0 C
+8
-8
Flash Point 0 C
160
120
PH
6.12
6.56
Kinematic Viscosity
7.08
7.52
Table 2. Temperature Results of 100% oils at 250 rpm spindle speed Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional oil
2
54
Neem oil
2
44
Water melon oil
2
47
Dry Sample
2
57
Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764 Table 3. Temperature results of 50% oils and 50% water at 250 rpm. Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional
3
45
Neem oil
3
38.1
Water melon oil
3
39.32
Dry Sample
3
51
Table 4. Temperature results of 25 % oils and 75% water at 250 rpm Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional
4
40.33
Neem oil
4
32.12
Water melon oil
4
34.12
Dry Sample
4
50
Table 5. Surface Roughness at 100 % oils at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
2
1.12
Neem oil
2
0.323
Water melon oil
2
0.312
Dry Sample
2
1.234
Table 6. Surface Roughness at 50% oil and water at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
3
1.01
Neem oil
3
0.002
Water melon oil
3
0.012
Dry Sample
3
1.113
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Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764 Table 7. Surface Roughness at 25% oil and 75 % water at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
4
0.945
Neem oil
4
0.0012
Water melon oil
4
0.0021
Dry Sample
4
1.001
1.5 Temperature results Table 2 shows the temperatures obtained machining at 100% oils at 250 rpm and depth of cut 2mm. Neem seed oil produced the better cooling effect with average temperature of 44°C. Result of water melon seed oil was 47°C averaged. The high temperature was obtained while machining dry sample and the temperature was 57 0 C. Conventional cutting oil resulted in the temperature of 54°C which was comparable to that of water melon seed oil. This result, also means that machining at 250 rpm, depth of cut 2mm, pure water melon seed oil and Conventional cutting oil inhibit even the natural air from cooling the work piece but however, acts as corrosion inhibitors since they create an interface between the work piece and air hence preventing oxygen from reaching or reacting with metal work piece. The second negative drawback of these pure oils is that led to high temperatures during the machining process. Table 3 shows temperatures obtained with 50% oils - water 50% water machined at a speed of 250 rpm, 3mm depth of cut. It showed that Neem seed has the better cooling effect of 38.10 C. Conventional cutting oil produces a temperature of 45°C. Water melon seed oil produced the cooling effect with temperature of 39.220 C. However when comparing with dry machined work piece (50°C), all three oils are effective as coolants. Table 4 shows temperatures obtained with 25% oils and 75 % water at 250 rpm, 4mm depth of cut. Results shows that neem oil and water melon oil performed better cooling effect than the conventional oil and dry sample. Neem seed oil produced the temperature of 32.12°C. This was closely followed by water melon oil with 34.12°C and conventional oil 40.33°C. 1.6 Surface roughness results At a speed of 250 rpm, 2 mm depth of cut and a constant feed rate of 0.50 mm the neem oil (100%) produced the best average surface finish having a roughness value of 0.323μm as given in Table 5. This was closely followed by water melon oil (100%) with 0.312μm and conventional oil (100%) with 1.12μm. The least quality surface finish were produced by the dry machined work piece 1.234μm [13]. The table 6 shows the surface roughness obtained at 250rpm, 3 mm depth of cut and the same feed rate of 0.50mm, neem oil produced the least surface roughness value of 0.002μm. This was followed by water melon oil with average surface roughness of 0.012μm and conventional cutting oil with 1.01μm.Dry sample surface roughness value with 1.113μm. It can be seen that with this emulsion ratio, some of the oils produced better surface finish than conventional cutting oil tested. Table 7 shows values of the average surface roughness obtained machining at 250rpm, 4mm depth of cut. Water Melon oil produced 0.0021μm while Neem oil produced 0.0012μm. These surfaces were better in quality than the Conventional cutting oil which produced 0.945μm and the Dry machined sample 1.001μm.Thus these roughness values shows that neem oil and water melon oil produces a lest roughness value with all concentration rates and it found to produce a better surface finish than conventional oil.
Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764
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1.7 Chip Formation For chips produced with 100 % oils, conventional oils produced blue black chips that are very short and discontinuous with maximum lengths of about 8mm and width of about 3 mm. Neem seed oil produced discontinuous chips of light silver to brown color, length of 5mm and width of about 1 mm. Water melon oil produced coil chips of about 6mm of average length, 2mm width having silver-white color (Fig. 1). At 50% oils and 50% water emulsions, conventional oil produced chips whose length is varying between 12mm to 26mm length and having width of about 1mm. Neem seed oil produced a mixture of open coil and discontinuous chips that are silvery white in color having length ranging from 6mm to 12 mm and width of about 2mm.Water melon produced chips that were a mixture of short and medium length coils averaging 8mm and 15mm with a silver color (Fig. 2). With 25% oils and 75% water emulsions, conventional oil produced semi spring-like chips that are dark blue-black color and have lengths varying between 10mm to 20mm with widths of between 1mm and 1.5mm (Fig.3). Neem seed oil produced short length coil chips that are silvery in color with length ranging from 5mm to 6 mm and width of 1mm while Water melon produced chips of closed coil with silvery color and length ranging from 6mm to 8mm and width 1mm. 2. Illustrations
(b) (a)
(b)
Fig. 1. (a) Water melon (100%); (b) Neem oil (100%)
(a)
(b)
Fig. 2. (a) Neem oil (50%); (b) Water melon oil (50%)
(a) Fig.3. (a) Neem oil (25%); (b) Water melon oil (25%)
Conclusion
It has been established that environmental-friendly vegetable-based oils are potential than compared to petroleum-based mineral oils as cutting fluids. Life and cutting ability of the tool is improved to large extent. Cooling property of neem and water melon vegetable cutting fluids gave a performance in comparison with that of conventional soluble oil, as indicated by slight temperature differences on the values obtained. Friction between the tool and the work piece is reduced. Productivity of the machined steel products increases. Neem and water melon oil are environment friendly than petroleum oil. Cost of the cutting fluids is considerably reduced. Better surface finish indicates that there is less friction and tool wear between tool and work piece in case of neem oil and water melon oil.
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Reference [1] A.K Singh and A.k Gupta (2006): Journal of synthetic lubrication; pages 167-176; [2] Motorucu, A. R. (2009): Surface roughness evaluation when machining carbon Steel with ceramic cutting tools. [3] Niraj Kumar Nayan (2011); a thesis submitted in the partial fulfillment of the requirement for the degree of Bachelor of Technology in Chemical Engineering, National Institute of Technology, Rourkela; pp28 &29. [4] Odjoba E. O, AIna O. E, Ayilara S. J., Joklo O (2002): Fatty Acids Profile and Physicochemical Properties of Citrullus Vulgaris. [5] Ojolo S. J; Amuda, M. O .H; Ogunmola O. Y, Ononiwu C. U; (2008): Journal of Material Rio de Janeiro vol. 13 No. 4 Rio de Janeiro. [6] Oyeleke, G.O., Olagunju, E.O., Ojo, A. (2012): Journal of Applied Chemistry (IOSR-JAC), ISSN: 2278-5736. Volume 2, Issue 2, PP 29-31. [7] Patrick Adebisi Olusegun Adegbuyi, Ganiyu Lawal, Oluwatoyin Oluseye, Ganiyu Odunaiya (2010): American journal of Scientific and industrial research. [8] Richard N. Callahan and Kevin M. Hubbard (2004): International journal of environmentally conscious design and manufacturing, Vol 12 No3. [9] S .J Ojolo and O. S Ohunakin (2011): Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 2 (1): pp 30-35. [10] Lawal, Sunday Albert; Mathew Sunday Abolarin, Benjamin Iyenagbe Ugheoke and Emmanuel Ojo Onche (2008): Journal of Practice/Technology; Online at lejpt.academicdirect.org/A10/137_144htm. [11] Susan Woods (2005): Going green; Cutting Tools Engineering Magazine, Vol. 57 No. 2. [12] Taiwo A. A, M O Agbotoba, J A Oyedepo, OA Shobo, I Oluwadare and M O Olawunmi (2008): American Journal of Food Agriculture Nutrition and Development (AJFAND), Vol. 8 No 4. [13] Thamizhmanii, S.,Saparudin, S.& Hasan, S. (2007): Journal of achievements in materials and manufacturing engineering, Volume 20 Issues 1-2, pp.503-506. [14] W A J Chapman (1972): Workshop Technology part 1, Fifth Edition; Edward Arnold Publishers Limited; pp 184-191. [15] Yeong S. K; (2003): Vegetable oil and its derivatives for lubricants; [Online] on 15/2/2012 at 5.14am. [16] Yuzan Yu, Yugao Guo, Lei Wang & Enqi Tang (2010): Journal of Modern Applied Science vol 4, No 1; pp53-58.
ScienceDirect Materials Today: Proceedings 5 (2018) 7758–7764
www.materialstoday.com/proceeding s
IMME17
Alternative Cutting Fluids for Metal Cutting Operations Lokesh Srinivasan1 S, Vimalathithan R, Manojkumar M V Sri Sairam Engineering College, West Tambaram, Chennai-600044,India.
Abstract In machining operation, the life of the tool is important as lot of heat energy is generated during machining process. Due to the heat developed the surface finish, dimensional accuracy and life of the material, which is machined is affected .There are different approaches under study to find an alternative. Thus neem oil and water melon seed oil was studied and made as an alternative as cutting fluids in order to improve the life of the tool, improve surface finish in work piece, prevent corrosion in a steel, maintaining dimensional accuracy. Rather than coating the tool to machine high strength alloys, it found to be a simple alternative. Physiochemical properties such as viscosity, flash point, pour point, specific gravity were studied. Specific gravity of Neem seed oil was 0.9304 and Water Melon seed oil was 0.9324. The flash point for Neem seed oil was obtained as 1750C, Water melon seed oil 130°C. Based on the property results machining operation is carried out at different spindle speeds with various ratio of both the oils and water. The best results were obtained with more absorption of heat energy and temperature was reduced than the current machining process, which will be explained briefly in the paper. All the oils – water emulsion ratios were effective as coolants and comparable to the petroleum oils. As in current machining process petroleum oil is used as a coolant but the availability and cost of the petroleum oils is critical. Thus there is a need for an alternative source of oil which could reduce the cost, increase its availability, prevents environmental pollution and should be a renewable one. Neem oil and water melon oil satisfies those conditions and it is not prone to workers as petroleum oil results is skin irritation and imbalance in health. In the current situation many industries are in need for alternative coolants to make the tools better usage for longer time period so it adds value to the work piece quantitatively and qualitatively and it helps in economic aspect of country too. © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering (IMME17). Keywords: Physiochemical properties; Neem oil;Water Melon Oil;Machining;Renewable.
1. Introduction The current market trend in renewable lubricant technology is making its stand in many industries and manufacturing sectors. It is driven by global warming, renewable resources, ethical corporate policies, cost of oil and government strategies to encourage vegetable oils in use. The researchers are making their interest in metal working fluids (MWF) which is termed as vegetable oils. People are interested in the conserving of the environment,
* Corresponding author. E-mail address: [email protected]
2214-7853 © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering (IMME17).
Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764
7759
health and safety of employees are given special care and enhancing the government economy and making the societies independent on oil [11]. Increasing demand for eco- friendly lubricant has led researchers to choose vegetable oils as the better alternative [15]. Modern metal working fluids are quite effective if environmental conservation is not included. Cost reductions are possible only through the performance increase in the areas which include life of the tool, surface finish of the machined product and enhanced cutting process speed and feeds [8]. However, when compared to conventional oil, vegetable oil can improve cutting performance, enhance tool life and surface texture is improved. Many new coolants have been developed to meet the needs of new materials, new cutting tools, new coatings on cutting tools. The goals of machining operations are to increase productivity in manufacturing sector and maintain accuracy at reduced cost. This is achieved by machining at the practical speed while maintaining practical tool life, reducing wear and producing parts with the desired surface finish or quality. During machining at practical speeds the work piece and the tool has the adverse effects based on its wear, surface finish and heat generated. Thus it is the challenging task to replace vegetable oils such as neem oil and water melon oil at this practical speeds and generate the optimized good results. 1.1 Experimental Methodology About 3 kg of neem seed samples are brought from the market. The seeds were sun dried in order to separate seed coat from the seed. Winnowing was carried out to separate and obtain clean seeds .The clean seeds were poured in Mortar and pestle to crush the seeds and obtain it in the paste like form. The neem paste is taken in the bowl and mixed with 300 ml of water. The proper mixing is done and then Neem paste is placed in the oven and the temperature was set in the range of 1200 C to 140 0 C and the heating was carried out for certain time period of 20 minutes. This temperature range is to increase the flow of oil during high pressure. In order to eliminate the complete oil from the seed paste was transformed to sieving cloth of very fine grade. Then the edges of sieving cloth were tied and the sieving cloth with neem paste was kept along with the mechanical press. Jack was used to apply the pressure continuously so that the oil is continuously squeezed out of the paste. The resulted neem oil is further processed for transesterification process in order to remove the fatty acids from it and to eliminate the nasty smell from it. Transesterification is the reaction between fat or oil with alcohol which result in glycerol and esters. This process was carried out until the complete oil is extracted from the paste and the oil was collected in the flask. The same procedure was repeated to extract the oil from water melon seeds. 1.2 Oil Properties The properties tested were given in Table 1 and compared with other results and it agreed with other results of researchers. Kinematic Viscosity of neem oil obtained at 120 0C as 7.08 which comparable with reference [1] but differ with [3]. Kinematic viscosity was calculated using ASTM D445. Water Melon had viscosity of 7.52. All results agreed with available literature on viscosities of oils. Viscosity plays a significant role on ability of oil to flow and also to remain stable at particular temperatures for a period of time. The pour point was obtained and it shows for all the oils, it can be poured relatively easily and hence the flow was not a problem. Neem had the least pour point of +8°C while Water Melon had the best result at -8°C. Pour point was calculated using ASTM D97. The flash point of neem and water melon was calculated using pensky-martens closed cup tester ASTM D93. The flash point of neem oil and water melon oil was 160 0 C and 120 0 C respectively. The pH of all the oils shows some level of acidity Neem oil had a pH of 6.12 and the pH of Water Melon was found to be 6.56. The low pH values support use of oils and it prevents the worker from skin irritation. Also, the tool and work piece are not corroded due to its pH value. However pH of 4.75- 9.75 is acceptable to the skin. This values are tested using pH meter. Sulphur content in oil plays a vital role too. Neem oil with 0.0293 %Sulphur which differs from 0.48 % from reference [3] and water melon %Sulphur was nil. The Sulphur content was very low in both the oils and it is tested using Horbia apparatus model SLFA2800 Sulphur in oil analyzer by X-RAY machine. Sulphur is used as an additive in lubricants and cutting fluids [7]. Since % Sulphur was low in oil samples, the Sulphur content can be added with few percentage to improve its function. Specific gravity is tested using ASTM D94 standard test procedure. Relative density result of water melon oil used was 0.9322. This compared closer to the value obtained in the reference [12]. Neem oil had relative density of 0.9302 which comparable to reference [3].
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Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764
1.3 Machining Process The work piece is fixed in the three jaw self-centering chuck of a lathe machine and properly tightened using chuck key. A high speed steel (HSS) is mounted on the lathe tool post. The tool is fixed with proper clearance and rack angle. The thermocouple wire (K TYPE) was set so that it just touched the cutting zone of the work piece. The thermocouple was then connected to digital electronic temperature indicating regulator of range (-200 0 C to 1350 0 C). This is the temperature at the cutting zone. Dry machining is carried out on a single work piece made up of mild steel of spindle speeds of 250 rpm. Readings were repeated so that average temperature was obtained. One vegetable oil (Neem oil) being tested was poured into water bottle used as the applicator and machining operation was carried out with oil applied from water bottle at speed of 250rpm. Machining operation was repeated with the Neem oil. The oil was then mixed with water at a 50% to 50% ratio and used to machine another work piece using the same parameters stated above and equally taking three readings. The Neem oil was again mixed with water at a ratio of 25% Neem oil to 75% water and the same procedure was repeated in carrying out the machining and recording. This machining process was carried out to get the results of temperature which get reduced due to the cooling property of the neem oil and water melon oil. 1.4 Table Results Table 1. Results of physiochemical analysis of two vegetable oils. Properties
Neem Oil
Water Melon oil
Specific Gravity
0.9302
0.9322
Pour Point 0 C
+8
-8
Flash Point 0 C
160
120
PH
6.12
6.56
Kinematic Viscosity
7.08
7.52
Table 2. Temperature Results of 100% oils at 250 rpm spindle speed Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional oil
2
54
Neem oil
2
44
Water melon oil
2
47
Dry Sample
2
57
Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764 Table 3. Temperature results of 50% oils and 50% water at 250 rpm. Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional
3
45
Neem oil
3
38.1
Water melon oil
3
39.32
Dry Sample
3
51
Table 4. Temperature results of 25 % oils and 75% water at 250 rpm Sample
Depth of cut (mm)
Machined reading(0 C)
Conventional
4
40.33
Neem oil
4
32.12
Water melon oil
4
34.12
Dry Sample
4
50
Table 5. Surface Roughness at 100 % oils at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
2
1.12
Neem oil
2
0.323
Water melon oil
2
0.312
Dry Sample
2
1.234
Table 6. Surface Roughness at 50% oil and water at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
3
1.01
Neem oil
3
0.002
Water melon oil
3
0.012
Dry Sample
3
1.113
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Lokesh et al., / Materials Today: Proceedings 5 (2018) 7758–7764 Table 7. Surface Roughness at 25% oil and 75 % water at 250 rpm Sample
Depth of cut (mm)
Surface Roughness(μm)
Conventional
4
0.945
Neem oil
4
0.0012
Water melon oil
4
0.0021
Dry Sample
4
1.001
1.5 Temperature results Table 2 shows the temperatures obtained machining at 100% oils at 250 rpm and depth of cut 2mm. Neem seed oil produced the better cooling effect with average temperature of 44°C. Result of water melon seed oil was 47°C averaged. The high temperature was obtained while machining dry sample and the temperature was 57 0 C. Conventional cutting oil resulted in the temperature of 54°C which was comparable to that of water melon seed oil. This result, also means that machining at 250 rpm, depth of cut 2mm, pure water melon seed oil and Conventional cutting oil inhibit even the natural air from cooling the work piece but however, acts as corrosion inhibitors since they create an interface between the work piece and air hence preventing oxygen from reaching or reacting with metal work piece. The second negative drawback of these pure oils is that led to high temperatures during the machining process. Table 3 shows temperatures obtained with 50% oils - water 50% water machined at a speed of 250 rpm, 3mm depth of cut. It showed that Neem seed has the better cooling effect of 38.10 C. Conventional cutting oil produces a temperature of 45°C. Water melon seed oil produced the cooling effect with temperature of 39.220 C. However when comparing with dry machined work piece (50°C), all three oils are effective as coolants. Table 4 shows temperatures obtained with 25% oils and 75 % water at 250 rpm, 4mm depth of cut. Results shows that neem oil and water melon oil performed better cooling effect than the conventional oil and dry sample. Neem seed oil produced the temperature of 32.12°C. This was closely followed by water melon oil with 34.12°C and conventional oil 40.33°C. 1.6 Surface roughness results At a speed of 250 rpm, 2 mm depth of cut and a constant feed rate of 0.50 mm the neem oil (100%) produced the best average surface finish having a roughness value of 0.323μm as given in Table 5. This was closely followed by water melon oil (100%) with 0.312μm and conventional oil (100%) with 1.12μm. The least quality surface finish were produced by the dry machined work piece 1.234μm [13]. The table 6 shows the surface roughness obtained at 250rpm, 3 mm depth of cut and the same feed rate of 0.50mm, neem oil produced the least surface roughness value of 0.002μm. This was followed by water melon oil with average surface roughness of 0.012μm and conventional cutting oil with 1.01μm.Dry sample surface roughness value with 1.113μm. It can be seen that with this emulsion ratio, some of the oils produced better surface finish than conventional cutting oil tested. Table 7 shows values of the average surface roughness obtained machining at 250rpm, 4mm depth of cut. Water Melon oil produced 0.0021μm while Neem oil produced 0.0012μm. These surfaces were better in quality than the Conventional cutting oil which produced 0.945μm and the Dry machined sample 1.001μm.Thus these roughness values shows that neem oil and water melon oil produces a lest roughness value with all concentration rates and it found to produce a better surface finish than conventional oil.
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1.7 Chip Formation For chips produced with 100 % oils, conventional oils produced blue black chips that are very short and discontinuous with maximum lengths of about 8mm and width of about 3 mm. Neem seed oil produced discontinuous chips of light silver to brown color, length of 5mm and width of about 1 mm. Water melon oil produced coil chips of about 6mm of average length, 2mm width having silver-white color (Fig. 1). At 50% oils and 50% water emulsions, conventional oil produced chips whose length is varying between 12mm to 26mm length and having width of about 1mm. Neem seed oil produced a mixture of open coil and discontinuous chips that are silvery white in color having length ranging from 6mm to 12 mm and width of about 2mm.Water melon produced chips that were a mixture of short and medium length coils averaging 8mm and 15mm with a silver color (Fig. 2). With 25% oils and 75% water emulsions, conventional oil produced semi spring-like chips that are dark blue-black color and have lengths varying between 10mm to 20mm with widths of between 1mm and 1.5mm (Fig.3). Neem seed oil produced short length coil chips that are silvery in color with length ranging from 5mm to 6 mm and width of 1mm while Water melon produced chips of closed coil with silvery color and length ranging from 6mm to 8mm and width 1mm. 2. Illustrations
(b) (a)
(b)
Fig. 1. (a) Water melon (100%); (b) Neem oil (100%)
(a)
(b)
Fig. 2. (a) Neem oil (50%); (b) Water melon oil (50%)
(a) Fig.3. (a) Neem oil (25%); (b) Water melon oil (25%)
Conclusion
It has been established that environmental-friendly vegetable-based oils are potential than compared to petroleum-based mineral oils as cutting fluids. Life and cutting ability of the tool is improved to large extent. Cooling property of neem and water melon vegetable cutting fluids gave a performance in comparison with that of conventional soluble oil, as indicated by slight temperature differences on the values obtained. Friction between the tool and the work piece is reduced. Productivity of the machined steel products increases. Neem and water melon oil are environment friendly than petroleum oil. Cost of the cutting fluids is considerably reduced. Better surface finish indicates that there is less friction and tool wear between tool and work piece in case of neem oil and water melon oil.
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