MEPCO SCHLENK ENGINEERING COLLEGE, (AUTONOMOUS) SIVAKASI

20MIS017 ROHIT S PPT VIDEO

OBJECTIVES. To eliminate the health hazards and environment hazards due to synthetic cutting fluids by replacing it with eco-friendly cutting fluids. To prepare non-toxic ecofriendly cutting fluids for machining of titanium alloy and Stainless steel. To preform characterization study of developed ecofriendly cutting fluids To test performance of newly developed ecofriendly cutting fluids for machining in industrials. To develop MQL (Minimum quantity lubrication) technique and D ry machining process in industrial machining applications..

ABSTRACT. Nowadays with growing pollution and contamination by chemical based cutting fluids, the scope for bio powders with distilled water based eco-friendly cutting fluids is increasing. The extracted bio powders can be used for making cutting fluids. Since there is no sedimentation of powders in distilled water. In this review work, the main focus is on sustainable machining using advanced cutting fluid application techniques with eco-friendly cutting fluids. Also , cutting fluid application techniques are equally important to minimize the use of cutting fluids for the desired machining processes. This project is on the unconventional cutting fluids, ecological aspects of unconventional cutting fluids, eco-friendly cutting fluids, cutting fluid application techniques during machining and their performances. An overview of the role of eco-friendly cutting fluids and cooling techniques are discussed and finally concluding remarks and possible scope of future work is presented..

INTRODUCTION. Cutting fluids are used to remove contaminates, to reduce friction in cutting area, and to inhibit corrosion. In beginning cutting fluids consists of coolant oils applied with brushes to lubricate and cool the machine tool. The cutting fluids are special blends of chemical additives, lubricants and water formulated to meet the performance demands of the metal working industry. This project reviews the common as well as some of the obscure environmental and health hazards along with methods been employed in recent years to prevent those shows the development of the discussion. The cutting fluids may cause health issues like throat, pancreas, rectum and prostate cancers, as well as respiratory problems, Skin infections to operator (Rashes, Irritation ). The usage of cutting fluids waste may affects the environment in growth of Enterobactersakazakii and Citrobacterdiversus species due to cutting fluids, Pathogens are also caused by bio deterioration as diseases. The low machinability materials such as Titanium grade 5 and Stainless steel is used for machining. This machining operation carries low machinability and cutting fluids are mainly used for machining. Then, the eco-friendly natural powders with mixture of distilled water is used as cutting fluids to prevent allergic exposure to workers and environmental impacts . And then added MQL Techniques and Dry machining process for analyzing the machining process by using natural powders cutting fluids for safe machining and safe work..

Bio powders preparation procedure. Rose petal powder, Hibiscus petal powder, Lotus petal powder, Andrographis Paniculata Powder.

Low Machinability. A material with poor machinability requires more power to cut , gives a poor surface finish and wears the cutting tool . Low Machinability Metals are Titanium Ti-6Al-4V Grade 5 Stainless steel Machining affects the Health and Environmental M achining produces many by-products or wastes including metal chips/swarf impregnated with cutting fluid, spent cutting fluid, oil contaminated water, oil mist, metal dust affects workers health and unnecessary energy usage affects the environmental conditions..

STAINLESS STEEL 304 ALLOY. TITANIUM GRADE 5 ALLOY.

After Lathe machining operation:. Titanium Grade 5.

Materials Specification. Titanium alloy Grade 5 alloys They are mixture of titanium and other chemical elements. Such alloys have very high tensile strength and toughness at extreme temperatures). They are light in weight, have extraordinary corrosion resistance and the ability to withstand extreme temperatures. The high cost of both raw materials and processing limit their use to military applications, aircrafts, space crafts, bicycle, medical devices, jewelry, highly stressed components. It is stronger than common, low-carbon steels, but 45% lighter. It is also twice as strong as weak aluminium alloys but only 60% heavier, 50 % lower modulus of elasticity (104 GPa ) and approximately 80% lower thermal conductivity than that of steel. Low elastic modulus – Titanium’s elasticity creates additional manufacturing challenges. Under cutting pressures, the material’s elasticity makes it spring away from the cutting tool, which causes edges to rub together (instead of cut), increasing friction and further raising the temperature at the cutting area. High chemical reactivity – Titanium has a tendency to weld to the tool during the machining process leading to chipping and premature tool failure. Low thermal conductivity – Increasing the temperature at the tool–work piece interface, thereby affecting tool life negatively . Hence, the selection of the proper metalworking fluid is essential..

Stainless steels 304 They are iron-base alloys that contain a minimum of about 12% Cr, the amount needed to prevent the formation of rust in unpolluted atmospheres. Few stainless steels contain more than 30% Cr or less than 50% iron . This oxide forms and heals itself in the presence of oxygen. Other elements added to improve particular characteristics include nickel, manganese, molybdenum, copper, titanium, silicon, niobium, aluminum, sulfur, and selenium. Carbon is normally present in amounts ranging from less than 0.03% to over 1.0% in certain grades . These applications include an extremely diversified range of uses, including nuclear reactor vessels, heat exchangers, oil industry tubulars, components for chemical processing and pulp and paper industries, furnace parts, and boilers used in fossil fuel electric power plants..

Bio powders heat extraction done separately for each powders:.

Bio-cutting fluids:. Lotus powder cutting fluids Ingredients: L inoleic acid (It keep skin safe and soft nature) P roteins , P hosphor , I ron V itamins A and B.

FTIR test for Rose powder. Saturday D«ernber 11, 2021 NO. Of Se.ns: 12.'1 Use r:.

FTIR test for Lotus powder:. Saturday, Decernber I 2021 8:02 PM 12," 1/2021 PM User:.

FTIR test for Hibiscus powder:. Saturday , December II, 2021 7:29 PM He.s.cug E SHIMAC>ZU User;.

FTIR test for Andrographis Paniculata ( Nilavembu ) powder:.

Herbal powder as cutting fluids laboratory report.

Coolant Cutting fluids. Figure 5. High thermal conductivity for cooling Good lubricating qualities. High flash point, should not entail a fire hazard Must not produce a gummy or solid precipitate at ordinary working temperatures Be stable against oxidation . Mixtures of water-soluble organic products with molecular dispersion. They do not contain mineral oil base or petroleum The material surface may be corroded after long-time exposure to cutting fluids. They are chemical based as Zinc dialkyl di thiophosphate ( ZDDP), Chlorinated paraffin's, Sulfurized lard oils, Phosphate esters, Over based calcium sulfonates. TYPICAL OBSERVATIONS Colour- Black and water mixed changes as White Appearance- Liquid Odour Mild Viscosity - 35.5 Flash Point (180°C ) Density - (25°C ) 7.34 Specific Gravity 0.88 Pour Point, ASTM D-97 - 15°C Solubility in Water Negligible Shelf Life (unopened container) 2 years.

Lab report for coolant cutting fluid:. • CHI • CHL•CHL• CHL• CHL• • • cm' • : 22311034 42179491 O CHENNRI METTEX LRB PRIVRTE LIMITED' 83. M. K. N. Chennai - 032. APEDA. AGMARK. GAETA. FSSAI. & TO ; Cust Ret Mepco C—. : 17.112021 22S2178 Test Wtho:d ASTM 0 2270 Appear—we G, S- RADHA — CFU — 25. Or. O. SATHYA NARAYANAN • • • • CHL • • • • CHL• •.

Metal coolant cutting fluids:. To act as a lubricant and coolant during metal fabrication To remove friction between the tool and the work piece while at the same time carrying heat that is generated away..

Experiment work done in Lathe Machine using Dynamometer and Thermal Camera device:.

Lathe working Experimentation video.

Thermal device images:. OZZ NII•Q z•z8.

Fluke Ti400 Thermal device specifications:. High performance, 320x240 thermal imaging camera for maintenance professionals Features Laser Sharp Auto Focus to produce consistently in-focus images. Offers Fluke Connect App to share results with remote users via a smart phone Measures temperatures from-20 °C to +1200 °C (-4 °F to +2192 °F) Provides IR Fusion technology with Auto Blend ™ mode to help clearly identify potential problems with precisely blended visual and infrared images Provides a one-handed, easy-to-use interface Offers faster communication with wireless image transfer directly to PC, Apple iPhone or iPad Includes backlit ruggedized LCD capacitive touchscreen Captures additional digital images to show location or additional site details with IR-Photo Notes ™ photo annotation system Digitally documents critical information along with the infrared image using IR-Photo Notes ™ or voice annotation Works with optional interchangeable lenses for greater flexibility in additional applications Includes rechargeable, field replaceable smart batteries with five-segment LED display to show charge levels Captures high definition visible light images with built-in 5-megapixel industrial performance digital camera Includes Fluke Connect® Smart View ® Analysis and Reporting Software.

Comparison analysis test readings in lathe machining.

Result outcome for using cutting fluid and bio cutting fluid Lathe machining cutting speed and Peak temperature graph:.

PROBLEM STATEMENT.

HEALTH HAZARDS RELATED TO CUTTING FLUIDS. Mineral oils or straight oils Skin Rash Burning contact Lung cancer Coughing problem Shortness of breath Non melanoma skin cancer.

HEALTH HAZARDS RELATED TO CUTTING FLUIDS. Animal oils Stinging eyes Hepatitis Influenza Malaria Dengue fever Weil’s disease.

ENVIROMENTAL HAZARDS RELATED TO CUTTING FLUIDS:. Water emulsions, pastes, gels, aerosols (mists ) Prostate cancers Bacteria Pathogens Throat soar Pancreas Rectum.

ORGAN, SKIN AND EYES ALLERGIES DUE TO CUTTING FLUIDS:.

Exposure of cutting fluids statistical data:. 8 E z 180 150 140 120 80 60 20 2004 2005 2007 20N 20G 2010 2011 2012 2013.

PROPERTIES OF TITANIUM TI-6Al-4V ALLOY. Thermal Properties Mechanical Properties Hardness Melting Point : 1604 – 1660 °C Boiling Point3133 K Solidus : 1604 °C Liquidus : 1660 °C Tensile Strength, Ultimate : 1170 Mpa Tensile Strength, Yield : 1100 Mpa Elongation at Break : 10% Modulus of Elasticity : 114 Gpa Density : 4.43 g/cc . 0.2% yield stress : 920 Mpa Reduction of area : 38% Brinell : 334 Rockwell : C 363.

PROPERTIES OF AUSTENITIC STAINLESS STEEL ALLOY. Thermal Properties Mechanical Properties Hardness Melting point of stainless steel – type 304 steel is around 1450°C The thermal conductivity of stainless steel – type 304 is 20 W/( m.K ) Yield strength of stainless steel – type 304 is 205 MPa. Yield strength of stainless steel – type 304L is 170 MPa. Ultimate tensile strength of stainless steel type 304 is 515 MPa. Ultimate tensile strength of stainless steel type 304L is 485 MPa. Good oxidation resistance in intermittent service to 870 °C, and in continuous service to 925 °C. It c ontaining 18%-20% chromium and 8%-10.5% nickel High corrosion resistance . Austenitic stainless steels are classified with AISI 200- or 300-series designations; the 300-series grades are chromium-nickel alloys, and the 200-series Brinell hardness of stainless steel – type 304 is approximately 201 Mpa Rockwell number – B85.

NOZZLES FOR CUTTING FLUIDS :. The nozzle performs four basic functions Atomizes liquid into droplets. Disperses the droplets in a specific pattern. Meters liquid at a certain flow rate. Provides hydraulic momentum ..

PROPOSED METHODOLOGY: PHASE-1.

PROPOSED METHODOLOGY PHASE-2.

MQL TECHNIQUE. It used to work with the compressor, the outlet air pressure control, inlet air pressure control, frequency valve, pump, and oil flow control. A precise pump is designed for the system which sends an adjustable amount of the lubricant (less than 200 mL/h) to the nozzle. The frequency valve calibrates the number of the fluid transmissions using the pump. The lubricant was guided to the nozzle which atomizes the oil to the droplets ranging from 15 to 40 µm During machining , the MQL nozzle could be placed in two positions relative to the tool so that the fluid sprayed onto the machining zone. During the machining experiments with MQL, the nozzles are placed in different arrangements to study the effect of nozzle position..

MQL TECHNIQUES IN DRY MACHINING. Given that MQL and Dry Machining rely on the heat being carried away by chips, good chip formation is essential . A critical component to good chip formation is good Feeds and Speeds. Invest in good coatings for your cutters. Heat is the enemy with MQL and Dry Machining . But good coatings such as Ti, SS not only protect against high heat, they often thrive on it. Through Spindle is advantageous for MQL just as it is with Flood Coolant. Shadowing effects where the MQL mist is blocked can make nozzle aim problematic without through spindle delivery. When using a cutoff tool on a lathe, the nozzle must spray from underneath up into the cut. Spraying from the top doesn’t work because the chip curls over the top of the cutter and blocks the oil. Get the nozzle close to the tool and work piece . MQL Oil will not travel as far as flood coolant . There’s less mist, but you will still want to use filters . Work hard to clear chips before they can transfer heat to the part. Do your highest heat operations at the end of the cycle, not the beginning. This reduces the dimensional changes. For example, operations that generate a lot of chips and especially where the chips will sit in contact with the part, are going to be the high heat operations. Avoid stringy chip nests by increasing feed rates or using serrated cutters. Reduce step over (Cut Width) to give the tool more “air time” so it can cool a bit more each revolution. Use CNC Machines with chip conveyors to get rid of chips before they transfer too much heat to the body of the machine. That heat will reduce the dimensional accuracy of your machine by causing thermal expansion ..

VISCOSITY INDEX OF CUTTING INDEX:. The viscosity of cutting oils is typically specified and measured at 40 °C. Some manufacturers test the oil additionally at 100 °C and state the viscosity index. Other test the kinematic viscosity at 100 °F (37.78 °C) or state Say bolt viscosity (SSU – Say bolt Seconds Universal) at 100 °F (and 210 °F ). Kinematic viscosity at 40 °C, 100 °F (37.78 °C), sometimes at 100 °C, sometimes with VI Dynamic viscosity at 25 °C Say bolt Universal Seconds (SUS; SSU) Density at 15 °C or 20 °C Specific gravity at 20 °C or 25 ° C Importance of viscosity is important for: Cutting oils, synthetic and semi-synthetic fluids. Further for concentrates before mixing them with water. Selection of the appropriate size and type of the fluid application system (pumps and nozzles). The design of bulk storage and delivery system for cutting oils, coolant concentrates and other compounds..

Cutting fluid & Type of Machining Operation Related Health risks Author Cutting fluid Mineral oil Type of Machining Operation Drilling Machine Material type AISI 316L stainless steel It causes skin rash, burning contact, lung cancer, coughing problem, shortness of breath, Non- melanoma skin cancer. The workers gets contact through working with the tool and work piece. E. Kuram, B. Ozcelik, E. Demirbas, and E. Sik.

Cutting fluid & Type of Machining Operation Related Health risks Author Cutting fluid Synthetic oil Type of Machining Operation Turning Machine, Grinding, Milling, Drilling machines Material type Titanium alloy It causes skin rash, itching or hives, swelling of the face, lips, or tongue; severe diarrhea, or difficulty breathing or shortness of breath. It allergies the human life as Dermatitis, skin disorders, cancer, Liver damage, reproductive damage, respiratory damage. Prolonged exposure of the skin or contact with cold surfaces can cause frostbite. O. Cakir, A. Yardimeden, T. Ozben, E. Kilickap.

Cutting fluid & Type of Machining Operation Related Health risks Author Cutting fluid Animal oil Type of Machining Operation Turning machine Material type Carbon steel or Plain carbon steel Exposure to cutting fluids may be a cause of Hepatitis , Influenza, Malaria, Dengue fever and Weil’s disease The possibility also exists of a hazard to the lungs from the inhalation of fumes in machine shops. This downtime may cause severe cellular damage. Alabi Ismaila Olanrewaju, Okediji Adebunmi Peter, Ogedengbe Temitayo Samson.

Cutting fluid & Type of Machining Operation Related Health risks Author Cutting fluid Gaseous based coolant lubricant fluid Type of Machining Operation Grinding machine Material type Nickel and Titanium alloy The most common diseases caused by metalworking fluids are skin diseases; problems of the respiratory tract, damage to lungs , brain and other disorders occur much less frequently. Irritant contact dermatitis is the most common skin disease in workers who come into contact with cutting fluids, followed by allergic contact dermatitis. Acute exposure at high levels causes dyspnea, violent cough, nausea, vomiting, lightheadedness, headache, chest pain, abdominal discomfort, and corneal burns, in addition to the same symptoms of low-level acute exposure. It also damage to living tissue, the central nervous system, severe illness, or even death. A.E.I.Elshwain, Norizah Redzuan, Noordin Mohd Yusof ..