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Comparison OF Lubricant Properties in Minimum Quantity Lubrication Machining

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Ambati Tejaswararao
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45 views

Comparison OF Lubricant Properties in Minimum Quantity Lubrication Machining

Project presentation templated a section on shock to you soon best of all time and I have to go with a grade ra ra ??????

Uploaded by

Ambati Tejaswararao
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 17

COMPARISON OF

LUBRICANT PROPERTIES
IN MINIMUM QUANTITY
LUBRICATION
MACHINING
A power point presentation by

1. A.Tejaswara Rao
DEPARTMENT OF MECHANICAL ENGINEERING (19A55A0322)
2. P.Sai venkata narasimha rao
(18A51A03A0)
ADITYA INSTITUTE OF TECHNOLOGY AND MANAGEMENT 3. G.Balu
(An Autonomous Institution)
(19A55A0316)
Approved by AICTE, Permanently affiliated to JNTU, Kakinada,
Accredited by NBA (AICTE) & NAAC (UGC) u/s 2(f) & 12(b)
4. M.Sainadh
K.KOTTURU, TEKKALI-532201, SRIKAKULAM Dist. (AP). (18A51A0389)

BATCH: 2018-2022
Under the guidance of
Contents:
• Objective
• Abstract
• Introduction
• Literature Survey
• Approach
• Application of the Project
• Expected Conclusions
Objective :
Comparison of Lubricant properties in minimum quantity lubriaction machining and
Reduction of tool wear and thermal stresses at the tool point.

Cutting operation with metalworking fluids. A view of minimum quantity lubrication,


sprayed with the help of nozzle (left). A view of conventional metalworking fluid, used as
coolant (right).
Abstract :
• Minimum Quantity Lubrication (MQL) machining involves the application of a
minute amount of an oil-based lubricant to the machining process in an attempt
to replace the conventional flood coolant system.
• Understanding the correlations between fluid properties and MQL performance
can help in selecting lubricants from a variety of choices without going through
extensive machining tests.
• This study compared nine different MQL fluids in terms of their physical
properties, wettability, tribological properties (lubricity and extreme pressure
(EP) properties), mist characteristics and machinability to determine the
correlation of measured properties.
Introduction :
• Machining is the wide spread metal shaping process, it consist rapid wear rate of
cutting tools due to high cutting temperature generated.
• Thus effective control of the heat generated during machining is essential to
ensure good workpiece quality. Different cutting fluids are applied to avoid
problem; however conventional cutting fluids are restricted due to their harmful
health and environmental impacts.
• The necessity to machine using less harmful cutting fluids has led the researchers
to develop new cutting fluids which are less harm and the result of the
investigation came up with a new systemied Minimum Quantity
• Minimum Quantity Lubrication refers to use the small amount of cutting fluid
typically in order of 500 ml/hr or less than that which is about 10,000 times less
than that of conventional cutting fluids.
There are 9 MQL lubricants that are going to test their properties

A. Biodegraded esters
B. Renewable acid esters
C. Naturally derived synthesis
D. Vegetable based
E. Vegetable based + EP
F. Biodegraded esters
G. Naturally occuring fatty oils
H. Synthetic esters
I. Vegetable based + EP
Types of MQL delivery system
There are two major delivery methods for MQL - one is an external application and
the other is an internal application. In the case of the external application, a mixture
of compressed air and oil is fed via an external nozzle to the cutting zone from a
chamber. In contrast to this, there are two possible methods for the external
application of oil and air or aerosol.
Ejector nozzle: The compressed air and oil are supplied to the ejector separately and
mixing occurs just after the nozzle.
Conventional nozzle: The aerosol is prepared in an external atomizer and then
transported to a conventional nozzle.
The internal delivery system of MQL is also known as a through-tool application,
where the
delivery of MQL is made through the spindle. There are two different
configurations available
Single-channel: The oil and compressed air are mixed before being
suppliedthrough the cutting tool to the workpiece/tool zone.
Dual-channel: The oil and compressed air are delivered in different
channels and are only mixed before the holder of the cutting tool.
Advantages of MQL

Financial Advantages:
• Due to omission of supply and disposal of coolant, high savings are possible.
• after optimization of processes, a higher tool life can be expected and also
reduce the machine cycle upto 30 ％ .
• There will be no expenditure for control and care of coolant.

Ecological advantages:
• No used emulsions will accumulate.
• Accidents due to large quantities of leaking coolant are avoided.
• Airway or skin diseases caused by coolants can be avoided.
Advancements in MQL
Although MQL is proven to be a good alternative for traditional flood cooling, its
cooling and lubricating effects are still in question. Therefore, researchers have
been exploring ways to enhance the effectiveness of MQL by improving both its
cooling and lubricating effects
Literature Survey :
• Boubekri & Shaikh, 2015 reported that the application of MQL based synthetic
ester as the cutting fluid was more efficient for the machining process as it reduced
the cutting temperature, cutting force, tool-chip contact length and produced better
chip thickness compared to dry machining technique.
• Madhukar et al, 2016 studied about the minimum quantity lubrication and
reported that MQL does generate a significant amount of mist compared to flood
cooling. However, minimum quantity lubrication, machining is safe for both
operators and environment, particularly when vegetable oil based lubricants are
used.
• Boswell Islam, 2012 Concluded that air cooling with the use of small amount of
vegetable oils is not a totally dry process it is quite close and therefore is a
sustainable. It also studied the effects of three parameters like cutting speed, feed
and depth of cut upon surface finish during milling operation and found that the
Approach:

• Nine MQL fluid test samples, named A to I, were acquired from six suppliers, and
their known physical properties are There is a large range in the viscosity of the
fluids (8.8 to 69 centistokes) and in the flash points (182 to 280°C). Fluid E is the
same as fluid D except for the addition of a sulfurized EP component.
• In this study, fluid B is used as the reference fluid to test against other commercial
MQL fluids since it is currently the standard fluid used in MQL machining tests at
General Motors. The evaluation metrics are divided into three groups:
• Physical properties: including density, viscosity, flash point, and thermal
conductivity. Since thermal conductivity information was not provided by the
supplier, it was measured in this study to complete the physical properties.
• Bench testing: Bench testing includes wettability, tribological properties and
mist characterization. Wettability was determined by the sessile drop method.
Tribological properties included lubricity and EP properties, measured with tapping
torque and pin-and-vee block methods, respectively. Mist characterization was the
measurement of the mist size and concentration generated by each fluid in the
machine enclosure.

• Machinability: Machinability referring to the ease with which a metal can be


machined to an acceptable surface finish. An aluminum transmission valve body
was adopted as the workpiece. The power consumption to drill and ream the spool
bores using different fluids was recorded, and the bore diameters and surface
roughness were measured and compared.
Application of the project:
• The most common high-volume production application for MQL is cross and oil
hole drilling on steel crankshafts. This paper reviews MQL test results for deep hole
drilling of forged steel and cast nodular iron under conditions similar to crankshaft
oil hole drilling.
• MQL can yield tool life equivalent to gun drills at higher penetration rates under
these conditions. This result is consistent with production experience with steel
crankshafts, and shows that MQL may also be useful for cross and oil hole drilling
of cast crankshafts.
• Limited test and production data for MQL machining of aluminum prismatics is
also described. Significant areas for future research and development, including
chip management, air quality, capability and robustness, and cost are also discussed.
Expected Conclusions :
• This study involved the evaluation of nine commercial MQL fluids and a
common Metal working Fluid (MWF) based on their thermal conductivity,
wettability, lubricity, External pressure(EP) properties, mist generation and
machinability to determine the importance of fluid properties are usually
straight oils.
• As shown in this study, this whereas MQL lubricants are Conventional MWFs
are typically waterbased difference translates into poorer heat removal
properties for the MQL lubricants compared to waterbased fluids, but
improved wettability and lubricity.
• Although it is difficult to draw relationships based on these experimental
results, the optimal machining under these mild machining conditions was
found with the low viscosity fluids, which corresponded to high mist
concentration, large droplet size and good wettability.
Resources and links :
•Hadad, M. and Sadeghi, B. Minimum quantity lubrication-MQL. turning of
AISI 4140 steel alloy.
•TIN top-coated insert with minimum quantity lubrication technology and
assessment of near tool-tip temperature using infrared thermography".
•Amrita, M., Srikant, R. R. and Sitaramaraju, A. V, "Performance evaluation of
nanographite-based cutting fluid in machining process", Materials and
Manufacturing Processes.
•Prasad, M.M.S., Srikant, R.R., "Performance evaluation of nano graphite
inclusion in cutting fluids with MQL technique in turning of AISI 1040 steel",
Int. J. Res. Eng. Technol. 2 (11), 2013, 381e393. [10] Itoigawa, F., Childs,
T.H.C., Nakamura, T, Belluco, W, "Effects and mechanisms in minimal
quantity lubrication machining of an aluminium alloy".
Thank you

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