CHAPTER – 1

INTRODUCATION

1.1 INTRODUCTION TO THE MINIMUM QUANTITY LIQUID

During cutting operations one of the most important problems is tool wear, caused by
the normal load generated by the interaction between tool and workpiece and by the relative
motion between tool ,chip , workpiece and tool . Tool wear, which results in tool substitution,
is one of the most important economical penalties to take into account during cutting. So it is
very important to improve tool life, minimizing the wear and optimizing all the cutting
parameters and factors: depth of cut, cutting velocity, feed rate, cutting fluids and cutting
fluids application. In cutting operations fluids play an important role. They must mainly
guarantee lubrication and cooling, secondly protect workpiece and tool from corrosion and
promote the chip evacuation.

1.2 LUBRICATION IN CUTTING

During cutting operations one of the most important problems is tool wear, caused by
the normal load generated by the interaction between tool and workpiece and by the relative
motion between tool and chip and workpiece and tool .Tool wear, which results in tool
substitution, is one of the most important economical penalties to take into account during
cutting, so it is very important to improve tool life, minimizing the wear and optimizing all
the cutting parameters and factors .depth of cut, cutting velocity, feed rate, cutting fluids and
cutting fluids application. In cutting operations fluids play an important role. They must
mainly guarantee lubrication and cooling, secondly protect workpiece and tool from
corrosion and promote the chip evacuation.

As far as lubrication is concerned, the load applied and the working conditions,
which characterize the cut, suggest that it is impossible continuously to lubricate the cutting
area by fluid film lubrication. So, to guarantee lubrication, it is necessary to use lubricant
with additives that chemically react with the workpiece and tool material to generate
chemical compounds that allow the lubrication of the cutting surface.

Moreover, the workpiece cooling is necessary to remove the heat generated during the
chip formation and by the friction between tool and workpiece. To reach the cutting surface is

1
not easy, in fact the high cutting pressure in the contact area and the small space between chip
and tool do not allow the cutting fluid to access this zone. In order to obtain a good cooling
action, the cutting area is generally flooded by lubricant. Finally, the cutting fluid flow can be
used to avoid the chip remaining in the cutting zone, so reducing the possibility of damaging
the workpiece. Many application methods can be used. Each application method is selected
depending on the advantages that it can give.

1.3 MINIMUM QUANTITY LUBRICATION

MQL, also known as “Micro lubrication”, and “Near-Dry Machining” is the latest
technique of delivering metal cutting fluid to the tool/work interface. Using this technology, a
little fluid, when properly selected and applied, can make a substantial difference in how
effectively a tool performs. In conventional operations utilizing flood coolant, cutting fluids
are selected mainly on the basis of their contributions to cutting performance. In MQL
however, secondary characteristics are important. These include their safety properties,
(environment pollution and human contact), biodegradability, oxidation and storage stability.

This is important because the lubricant must be compatible with the environment and
resistant to long term usage caused by low consumption. In MQL, lubrication is obtained via
the lubricant, while a minimum cooling action is achieved by the pressurized air that reaches
the tool/work interface. Further, MQL reduces induced thermal shock and helps to increase
the workpiece surface integrity in situations of high tool pressure.

FIG 1.3.1 MINIMUM QUANTITY LUBRICATION

2
1.4 GENERAL REQUIREMENTS FOR MQL

The main task of the MQL systems is the targeted supply of an appropriate lubricant
to the contact point of the tool (cutting edge). A number of different devices for various
requirements are available for this purpose. For single-purpose machines, e.g. broaching,
sawing and shaping, simple, manually controllable MQL devices with internal and external
feeds with different functional modes are normally used. They are usually systems with
pressure tanks and metering pumps. Modern flexible production systems require very
demanding MQL device technology. For this purpose, complex MQL systems have been
developed that have integrated components for regulation, control and monitoring.
Depending on the accessibility to the cutting edge, different requirements apply to the devices
in use. For this reason, a differentiation is made between external and internal feed of the
lubrication medium, which makes a noticeable difference to the cost of the device
technology.

In the case of external feed, the lubricant is applied by means of spray nozzles around
the circumference of the tool. This system is especially suitable for entrance-level
implementation for standard processes (turning, milling, drilling). With internal feed, the
lubricant is transported through the spindle system of the machine and through the channels
in the tool to the machining point. This system is used primarily when flexible processing
centres and new machinery are in use as well as with high-speed cutting (HSC). The different
device technologies and their purposes, as well as advantages and disadvantages, are describe
below.

FIG 1.4.1 GENERAL REQUIREMENTS FOR MQL

3
1.5 TYPES OF MQL SYSTEM

There are two basic types of MQL delivery systems: external spray and
through-tool. The external spray system consists of a coolant tank or reservoir which is
connected with tubes fitted with one or more nozzles. The system can be assembled near or
on the machine and has independently adjustable air and coolant flow for balancing coolant
delivery.

It is inexpensive, portable, and suited for almost all machining operations.

Through-tool MQL systems are available in two configurations; based on the method of
creating the air-oil mist. The first is the external mixing or one-channel system. Here, the oil
and air are mixed externally, and piped through the spindle and tool to the cutting zone.

The advantages of such systems are simplicity and low cost; they are suited to
be retrofitted to existing machines with high-pressure, through the tool coolant capability.
They are easy to service; no critical parts are located inside the spindle. The disadvantage is
that the oil-mist is subjected to dispersion and separation during its travel from the nozzle.

To minimize oil drop outs, a mist of relatively fine particles is used, which
often limits the amount of lubrication that can be supplied to the cutting zone and
consequently affects the performance of the cutting process. The second configuration is the
internal mixing or two channel systems. Most commonly in a two channel system, two
parallel tubes are routed through the spindle to bring oil and air to an external mixing device
near the tool holder where the mist is created.

This approach requires a specially designed spindle. Such systems have less
dispersion and dropouts and can deliver mist with larger droplet sizes than external mixing
devices. They also have less lag time when changing tools between cuts or oil delivery rate
during a cut. However, the systems are more difficult to maintain; critical parts are located
inside the spindle.

4
 CHAPTER-2

LITERATURE REVIEW

2.1 LITERATURE REVIEW

In Optimization Of Minimum Quantity Lubrication Parameters In High Speed

Turning Operation Journal D. G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan Says
That Minimum quantity lubrication (MQL) refers to the use of cutting fluids of only a minute
amount—typically of a flow rate of 50–500 ml/h which is about three to four orders of
magnitude lower than the amount commonly used in flood cooling condition. Minimum
quantity of lubrication (MQL) in machining is an alternative to completely dry or flood
lubricating system, which has been considered as one of the solutions for reducing the
amount of lubricant to address the environmental, economical and mechanical process
performance concerns. Lubricant concentration in MQL varies between 0.2 and 500 ml/hr.,
and does not recirculate through the coolant delivery system. Since very good lubrication
properties are required in MQL, MQL oil or synthetic easter oil are used instead of mineral
oil. Air pressure is roughly 5 bars. MQL is consumption lubrication, that is, the bulk of the
lubrication applied is evaporated at the point of application. This evaporation in concert with
the compressed air stream, cools the workpiece. This paper deals with the practical
development of the MQL technology for the milling and drilling processes that are conducted
by machining centers. A significant feature of the proposed technology is that it can be
applied for the existing machine tools by attaching a specially designed tool holder. Special
attention is also paid to developing the type of oil that is suitable for the MQL technology. An
attempt for completely avoiding the use of cutting fluids, i.e., dry cutting under the
atmosphere of nitrogen gas is briefly introduced as well.
Pauls and Chattopadhaya also studied effectiveness of cryogenic coolant. It
reduced the magnitude of tensile residual stress for all materials, although to varying degrees,
under all feed levels. This was attributed to the efficient cooling action, better modes of chip
formation, less specific energy, and finally lower grinding zone temperature.
Popke et al reported longer tool life with a minimum quantity of cutting fluid
application (MQCFA) as compared with dry and flood type application while drilling counter

5
boring and reaming steel material C45 and is clear that MQCFA is more appropriate with
high speed steel tools for clean manufacturing,
Bennett studied the overall effect of cutting fluids on the worker safety and on the
environment through bacterial cultures. In some applications the consumption of cutting
fluids has been reduced drastically by using mist lubrication. However mist in the industrial
environment can have a serious respiratory effect on the operator. Many researchers have
suggested the minimum quantity of lubrication techniques in machining process.
Machhado and wall Bank and Rahman et.al applied this technique in reaming
process of grey ,C.I. and aluminium alloy with coated carbide tools. The significant reduction
in tool wear and improvement in surface quality of the holes have been observed using MQL
technique when compared to dry cutting.
Dhar et al employed MQL technique turning of AISI 1040 steel and the results
clearly indicated that a mixture of air and soluble oil machining is better than conventional
flood coolant system. That appeared to be ineffective for applications involving high
temperature. Another study focused on the use of solid lubricant (boric acid and MoS2) in
forming and drilling [20]. In metal forming applications [21] it is shown that the boric acid
provided very low friction between an aluminium work piece and steel forming tool.
Graphite and molybdenum disulphide assisted end milling process has shown considerable
improvement in the process performance as compared to that of machining with cutting fluid
in terms of cutting forces, surface quality and specific energy . Solid lubricants like MoS2,
MoS2 base grease, graphite based grease and silicon compound mixed with SAE20 oil have
indicated the improved surface quality in different proportions while machining aluminium
and brass . The above mentioned studies indicate that the surface finish can be improved by
reducing the tool wear. Dry machining and machining with the flooded cutting fluids have
not responded to improved tool life and surface finish. The use of minimum quantity of
lubrication method in metal cutting may be a viable alternative to cutting fluids (flooded
condition) as has been reported in some of the above mentioned studies. Hence an attempt
has been made in the present work, 10% boric acid by weight mixed with SAE 40 base oil is
used as minimum quantity of lubrication during turning of HS316-Lsteel using tungsten
carbide cutting tool. Cutting temperature (chip-tool interface temperature), cutting force, chip
thickness and surface roughness were measured during turning process. The effectiveness of
minimum quantity lubricant is compared with that of dry machining.

6
 In today’s competitive manufacturing environment, the enhancement of productivity
with improved product quality and reduced cost, as well as the maximization of the profit
decides the sustainability of a manufacturing organisation. The major problems in achieving
high productivity and quality are caused by the high cutting temperature developed during
machining, at high cutting velocity and feed rates, particularly when the work material is
difficult to machine. In general, the condition of the cutting tools plays a significant role in
achieving consistent quality, and also in controlling the overall cost of manufacturing.

The above objectives can be achieved by reducing the high cutting temperature in the
cutting zone. Such high temperature adversely affects the tool life, dimensional accuracy and
surface integrity of the product. Increased cutting force, excessive tool wear, poor surface
finish, poor dimensional stability, etc. are temperature-dependent side effects; they are also
interdependent and are the major concerns in the metal cutting industry.

The high cutting temperature can be reduced and sustainable high productivity with
acceptable product quality achieved by optimum selection of the machining parameters, and
proper cutting fluid application, and by using heat resistant tools. In industries, the high
cutting temperature and its detrimental effects are generally tried to be controlled, by
applying soluble oil as a conventional coolant. These fluids act both as coolants to reduce the
tool temperature, and also as lubricant . According to Klocke and Eisenblatter (1997), the
flood type cutting fluid is generally adopted to reduce the cutting temperature, and lubricate
the sliding surface during machining.

7
 CHAPTER -3

METHODOLOGY

3.1 METHODOLOGY

In the present study, six parameters at two levels were determined

through preliminary experiments are quantity of lubricant (Q), delivery pressure at the nozzle
(P), frequency of pulses (N), direction of application of cutting fluid (D), cutting speed (Vc)
and feed rate (f). These parameters were used as a input process parameters. The output
parameter used as performance indicator is flank wear. Tungsten carbide (K20) insert was
used due to its low cost as a cutting tool material for optimizing the minimum quantity
lubrication parameters in pulsed jet mode.

FIG 3.1.1 METHODOLOGY

8
 CHAPTER-4

DETAILS OF COMPONENTS

4.1 MATERIALS USED

 HS 316-L STEEL
 Boric acid
 SAE-40 oil
 Tee joint
 Ball valve
 Coupling
 Hose nipple
 Hose
 Pressure gauge
 Plumping thread

4.1.1 HS 316-L STEEL

Grade 316L, the low carbon version of 316, is highly resistant to sensitisation
(grain boundary carbide precipitation) and so is extensively used in heavy gauge welded
components (about 5mm and over). Grade 316H, with its higher carbon content has some
application at elevated temperatures, as does stabilised grade 316Ti. Nitrogen-strengthened
versions also exist as 316N and 316LN. Only 316 and 316L are readily available in
Australian stock.

9
 FIG 4.1.1 HS 316-L STEEL

PROPERTIES

 Subject to pitting and crevice corrosion in warm chloride environments, and

to stress corrosion cracking above about 60°C.

 Good oxidation resistance in intermittent service to 870°C and in continuous

service to 925°C.

4.1.2 BORIC ACID

Boric acid, also called hydrogen borate, boracic acid, orthoboric acid and acidum
boricum, is a weak, monobasic Lewis acid of boron often used as an antiseptic, insecticide,
flame retardant, neutron absorber, or precursor to other chemical compounds. It has the
chemical formula H3BO3 (sometimes written B(OH)3), and exists in the form of colourless
crystals or a white powder that dissolves in water. When occurring as a mineral, it is called
sasolite.

10
 FIG 4.1.2 BORIC ACID

PROPERTIES

 Boric acid is a solid lubricant

 It has a excellent lubricant properties

 It available cheap and environmental safety

 Density of boric acid =1.44 g/cmᶟ

4.1.3 SAE – 40 OIL

SAE 40 is synthetic oil derived from natural or crude oil. Here, SAE stands for Society
of Automotive Engineers and 40 refers to viscosity of the oil. In layman's term we can say 40
is thickness of oil. More is the thickness, lesser is the contact between metals, which
increases the life of engine. More is the thickness, slower is speed or flow of the oil.

These lubricants in IC engines are used for reducing wear and tear, inhibiting
corrosion and provide sealing. They also help in heat dissipation.

SAE stands for Society of Automotive Engineers and 40 is grade , higher the grade
,higher is the viscosity.

11
 FIG 4.1.3 SAE – 40 OIL

PROPERTIES

 SAE-40 base oil is chosen as mixing medium

 It has higher viscosity

 Hence improve minimum quantity lubricant

 It has reduced wear and tear

4.1.4 TEE JOINT

An electrical connection used for joining a branch conductor to a main conductor

where the main conductor continues beyond the branch.

12
 FIG 4.1.4 TEE JOINT

4.1.5 BALL VALVE

A. one-way valve that is opened and closed by pressure on a ball which fits into
a cup-shaped opening.

FIG 4.1.5 BALL VALVE

4.1.6 COUPLING

A coupling is a device used to connect two shafts together at their ends for the
purpose of transmitting power. Couplings do not normally allow disconnection of shafts
during operation, however there are torque limiting couplings which can slip or disconnect
when some torque limit is exceeded.

13
 FIG 4.1.6 COUPLING

4.1.7 HOSE NIPPLE

In plumbing and piping, a nipple is a fitting, consisting of a short piece of pipe,

usually provided with a male pipe thread at each end, for connecting two other fittings. The
length of the nipple is usually specified by the overall length with threads

FIG 4.1.7 HOSE NIPPLE

4.1.8 HOSE

A hose is a flexible hollow tube designed to carry fluids from one location to
another. Hoses are also sometimes called pipes or more generally tubing

14
 FIG 4.1.8 HOSE

4.1.9 PRESSURE GAUGE

Many techniques have been developed for the measurement of pressure

and vacuum. Instruments used to measure and display pressure in an integral unit are called
pressure gauges or vacuum gauges. A manometer is a good example as it uses a column of
liquid to both measure and indicate pressure. Likewise the widely used bourdon gauge is a
mechanical device which both measures and indicates, and is probably the best known type
of gauge.

FIG 4.1.9 PRESSURE GAUGE

15
4.1.10 PLUMPING THREAD

The thread is a designation for BSPT (British Standard Pipe Taper). For
example ... refers to the threaded end of a fitting or pipe which is 1/4 inch trade size (not
actually 0.25 inches), and having British Standard Tapered Pipe threads.

FIG 4.1.10 PLUMPING THREAD

4.2 EQUIPMENTS USED

 Magnetic stirrer
 Lathe tool dynamometer

4.2.1 MAGNETIC STIRRER

A magnetic stirrer or magnetic mixer is a laboratory device that employs a

rotating magnetic field to cause a stir bar (also called "flea") immersed in a liquid to spin very
quickly, thus stirring it. The rotating field may be created either by a rotating magnet or a set
of stationary electromagnets, placed beneath the vessel with the liquid.

16
 FIG 4.2.1 MAGNETIC STIRRER

4.2.2 LATHE TOOL DYNAMOMETER

This is a strain Gauge Type two/three component Lathe Tool

Dynamometer designed to measure vertical & horizontal / (radial force in case of three
component ) forces on tool during cutting process. The unit consists of a mechanical sensing
unit or tool holder and digital force indicator. With this dynamometer, students can study the
change in these forces due to change in speed, feed and depth of cut.

FIG 4.2.2 LATHE TOOL DYNAMOMETER

17
 CHAPTER-5

COMPOSITION AND CHARACTERISTICS OF MQL

5.1 PREPARATION OF MINIMUM QUANTITY LIQUID

Minimum quantity liquid prepared by a combination of SAE 40 is synthetic oil

derived from natural or crude oil and mix with combination of boric acid chemical formula
H3BO3 .Boric Acid convert kilogram in to litre. boric acid .and SAE 40 oil are taken in bekkar
and mix in correct proportions required for turning operation in lathe.
Magnetic stirrer or magnetic mixer is the equipment we take to mix a correct
quantity of SAE 40 and boric acid. The magnetic stirrer equipment well mixes a given
quantity of oil and boric acid. The oil colour and density, viscosity is changed for required
level to a operation in lathe.

Fig 5.1.1 PREPARATION OF MINIMUM QUANTITY LIQUID

TABLE 5.1.1 COMPOSITIONS OF MQL

S.NO

2
5.2 MODEL CALCULATION

Litre = kilogram / density

For example 1000 kg of boric acid

1 litre = 1000/1.44
= 694.45 g

5.3 MINIMUM QUANTITY LIQUID LUBRICANT CHARACTERISTICS

Lubricant concentration in MQL varies between 0.2 and 500 ml/hr., and
does not recirculate through the coolant delivery system. Since very good lubrication
properties are required in MQL, Air pressure is roughly 5 bars. MQL is consumption
lubrication, that is, the bulk of the lubrication applied is evaporated at the point of
application. This evaporation, in concert with the compressed air stream, cools the work
piece. The remaining heat is dissipated through the tool and the chips. The chips, work piece
and tool remain nearly dry in an ideally adjusted MQL system. synthetic polyol esters and
described their capabilities as MQL fluids. These represent a potential replacement for MQL-
based MQL oils, particularly with regard to their optimal secondary performance
characteristics .All MQL oils display high biodegradability. Synthetic esters, however,
provide a wide range of biodegradability depending on their combined molecular structures
of acids and alcohols. This characteristic, in conjunction with their suitable viscosities,
prompted Wakabayashi, et al., to identify these lubricants for further examination.
Physical properties and biodegradability of polycol esters were
compared with MQL oil. The viscosity, total acid number, pour point and biodegradability for
polycol ester oil were 19.1 mm2/s, 0.02 mg KOH/g, 45˚ C and 100% respectively. These
characteristics for MQL oil were 35.6 mm2/s, 0.04 mg KOH/g, 20˚ C and 98% respectively.
The molecular weights of polycol ester oil and MQL oil were also compared. The molecular
weight of the oil film increased by more than 10%.The molecular weight of MQL oil
increased by 65%. In contrast, there was no significant change in the molecular weights of
polyol esters. Most MQL oils consist of a number of ester compounds mainly derived from a
combination of glycerine and fatty acids.

19
 MQL oils are usually liquids at room temperature, due to their
unsaturated bonds. Unfortunately, unsaturated bonds are chemically unstable and may cause
MQL oils’ molecular weight to increase. A detailed investigation of behaviour was carried out
using GPC analysis. The results indicated that some of the molecules in MQL oil had
changed into compounds having higher molecular weights. Results of the UV analysis, which
can selectively detect changes in unsaturated double bonds, indicate the unsaturated structure
decreased significantly. This result supports the hypothesis that the unsaturated bond structure
of MQL oil molecules is the main cause of their easy degradation by oxidation
polymerization. The chosen as preferable biodegradable lubricants in this investigation are
synthesized from a specific boric acid alcohol rather than glycerine. Their molecules can
greatly improve oxidation stability; they are free from unsaturated bonds. Regardless, they
can be liquid at room temperature. Compared with MQL oils, the synthetic studied were
optimal lubricants for MQL machining from the standpoint of maintaining a clean working
environment. Another secondary characteristic studied concerned the long-term storage
potential of MQL oils. Lubricant containers are often stored outside, and the temperature in
the containers can rise as high as 70˚C. Since an MQL system consumes very little lubricant,
the lubricant must remain stable under such conditions. In order to simulate this storage
situation, an oxidation test was conducted at 70˚C for 4 weeks. Changes in viscosity and total
acid number (TAN) were measured. The change in viscosity for polyol ester oil and MQL oil
after the storage stability test were 0.01% and 1.5% and the change in Total Acid Number
(TAN) were 0.01% and 0.18% respectively. While the viscosity and TAN of polyol ester were
almost constant, the values for MQL oil increased considerably. These results confirm the
stability of the molecular structure of the synthetic esters regarding oxidative degradation,
thus promoting their stability in storage.
TABLE 5.3.1 CHARACTERISTICS

S.NO PROPERTIES

1 Viscosity

2 TAN – total acid number

3 Air pressure

4 Pour point

20
 CHAPTER – 6

WORKING PRINICIPLE

6.1 WORKING PRINCIPLE OF MINIMUM QUANTITY LIQUID

The MQL needs to be supplied at high pressure and impinged at high

speed through the nozzle on the cutting zone. Considering the conditions required for the
present research work and uninterrupted supply of MQL at a constant pressure of around 6
bar over a reasonably long cut, a MQL delivery system was designed, fabricated and used. In
this system, a compressor was used to supply air at a high pressure of 10 bar.

This high pressure air from the compressor entered into two chambers
like fluid chamber and mixing chamber at two different but preselected pressures of 10 and 6
bar respectively. The fluid chamber was connected at the bottom with the mixing chamber by
very small diameter flexible tube. This tube was passed through a roller type flow controller
to permit a little amount of fluid to flow under high pressure.

The compressed air entering into the inlet port created pressure to cause
the fluid to flow continuously to the mixing chamber through controller at a constant rate.
The air and the oil were mixed in the mixing chamber so that the mixture of MQL oil and air
impinged at a high velocity through the nozzle on the chip–tool interface. During
experimentation, the thin but high velocity stream of MQL was projected at the tip of the
cutting tool along the auxiliary cutting edge making an angle 15◦ with it. Consequently, the
coolant reached as close to the chip–tool and the work tool interfaces as possible. The MQL
jet was used mainly to target the rake and flank surface and to protect the auxiliary flank to
enable better dimensional accuracy.

The effectiveness, efficiency and overall economy of machining of any

work material by given tools depend largely on the machinability characteristics of the tool
work materials under the recommended condition. Machinability is usually judged by (i)
cutting temperature, which affects product quality, and cutting tool performance (ii) pattern
and mode of chip formation (iii) magnitude of the cutting forces, which affects power
requirement, dimensional accuracy and vibration (iv) surface finish and (v) tool wear and

21
tool life. In the present work, cutting temperature, chip pattern, chip formation mode, tool
wear and surface roughness were considered for studying the role of minimum quantity
lubrication.

FIG 6.1.1 WORKING PRINCIPLE OF MINIMUM QUANTITY LIQUID

6.2 EXPERIMENTAL CONDITIONS AND PROCEDURE

Experiments were carried out by plain turning a 100mm diameter and

710mm long rod of HS316-L steel of common use in a powerful and rigid lathe (France,
15hp) at different cutting velocities and feeds under dry, wet and MQL by MQL oil
conditions. These experimental investigations were conducted with a view to explore the role
of MQL on the machinability characteristics of that work material mainly in terms of cutting
temperature, chip formation, tool wear and surface roughness. The experimental conditions

22
are listed in. The ranges of the cutting velocity (Vc) and feed rate (S) were selected based on
the tool manufacturer’s recommendation and industrial practices. Depth of cut was kept fixed
to only 1.0mm, which would adequately serve the present purpose. Machining ferrous metals
by carbides is a major activity in the machining industries. Machining of steels involves more
heat generation for their ductility and production of continuous chips having more intimate
and wide chip–tool contact. Again, the cutting temperature increases further with the increase
in strength and hardness of the steels for more specific energy requirement. Keeping these
facts in view, the commonly used alloy steel like HS316-L was considered in this
experimental research.

FIG 6.2.1 EXPERIMENTAL CONDITIONS AND PROCEDURE

23
6.3 EXPERIMENTAL DESIGN

In the present study, three parameters, namely, Quantity of lubricant (Q),

Cutting speed (Vc) and Feed rate (f) were identified and the ranges of the cutting conditions
were determined through preliminary experiments. Each parameter was investigated at three
levels to study the non-linearity effect of the parameters. Design of the experiments was
chosen full factorial and the identified parameters and their associated levels are given in
Table 1.

TABLE 6.3.1 MACHINING PARAMETERS

24
Fig 6.3.1 MACHINING PROCESS

FIG 6.3.2 MACHINING PROCESS

25
 CHAPTER – 7

RESULT AND ANALYSIS

7.1 EFFECT OF PARAMETERS

The following parameters are taken for analysis in our project. The effect of different
parameters are following.
 Quantity of lubricant (q)

 Cutting speed (Vc)

 Feed rate (f)

On surface roughness by carbide tool that it designed with mini tab software. The
result of figure shows, by increasing the cutting speed from 150 to 200 m/min, surface
roughness value is decreased because by increasing cutting speed in defined range that this
defined range depend on the material work piece and used tool.

TABLE 7.1.1 PARAMETER OF MQL CONDITION

S.NO

TABLE 7.1.2 CUTTING SPEED VS QUANTITY

26
 GRAPH 7.1.1 CUTTING SPEED VS FEED

GRAPH 7.1.2 CUTTING SPEED VS QUANTITY

By increasing the cutting speed from 200 to 250 m/min surface roughness value is
increased and the optimization result indicated that cutting speed of 200m/min is the best
condition of machining to minimize surface roughness.

By increasing the feed rate surface roughness value is increased and the result
indicated that feed rate of 0.08 mm/rev is the best condition of machining to minimize
surface roughness.

By increasing the quantity of lubricant from 100 to 200 ml/h, surface roughness value
is decreased. By increasing the cutting speed from 200 to 250 ml/h surface roughness value is
increased and 200ml/h is the best condition of MQL to minimize surface roughness.

27
7.2 EFFECT OF MQL ON MAIN CUTTING FORCE

The comparison of cutting force for HS316-L steel with feed rates for different cutting
speeds under dry machining and MQL technique were shown in fig. It clearly appears that
cutting force increases with the increase in feed rate due to increase in chip load also cutting
force decreases with increase in cutting speed due to decrease in shearing area. The result
indicates that decreased cutting force in MQL machining as compared to dry machining.

The lubricant effectiveness in minimizing the frictional affects at the tool and work-
piece interaction in case of minimum quantity of lubrication assisted machining is evident
from the reduced cutting forces compared to dry metal cutting. This performance of MQL
containing boric acid is due to its lattice layer structure allows it to act as an effective solid
lubricant film.

Crystallized boric acid forms weak Vander wall bonds between individual layers and
strong hydrogen (covalent) bonds within the layer. Such a bonding structure makes the
structural properties of boric acid highly anisotropic. When tangentially loaded, the
individual lamellae slide relatively easily over the.

This is in contrast to the normal direction where the boric acid has a relative high load
carrying capacity. Hence, when properly aligned with substrate, boric acid will exhibit
minimal friction and provide effective separation between work piece and tool surfaces.

28
 TABLE 7.2.1 FEED RATE VS MAIN CUTTING FORCE IN DRY CONDITION

S.NO

10

11

12

TA

S.NO

10

11
 12

29
GRAPH 7.2.1 FEED RATE VS MAIN CUTTING FORCE IN DRY CONDITION

GRAPH 7.2.2 FEED RATE VS MAIN CUTTING FORCE IN MQL CONDITION

30
7.3 EFFECT OF MQL ON CHIP THICKNESS

The chip thickness is a parameter that is used to understand the basic metal cutting
process. The comparison of chip produced is one of the major parameters influencing
productivity in metal cutting industry. A lower chip thickness implies better lubrication at the
chip-tool interface and formation of chips of thinner sections i.e. if the chip thickness
decreases, the process efficiency goes up. The chips were collected at the end of each
experiment and the chip thickness was measured using slider vernirecaliper. The chip
thickness values, obtained during dry and MQL assisted machining for particular cutting
conditions were shown in figures shows the chip thickness for dry and MQL machining of
HS316-L steel. It clearly reveals that increase in chip thickness with the increase in the feed
rate and also the decrease in chip thickness with the increase in cutting speed. The reduction
in chip thickness was observed to be maximum of 12% in minimum quantity of lubrication
technique. This is because of better lubrication effect produced by the minimum quantity
lubricant (10% boric acid with SAE 40 base oil at the chip-tool interface due to the formation
of fluid cushion. Reduced chip thickness in minimum quantity lubricant machining results
from the lowered cutting temperature and reduced adhesion between the tool and chip.

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TABLE 7.3.1 FEED RATE VS CHIP THICKNESS IN DRY CONDITION

S.NO

TABLE 7.3.2 FEED RATE VS CHIP THICKNESS IN MQL CONDITION

S.NO

9
32
GRAPH 7.3.1 FEED RATE VS CHIP THICKNESS IN DRY CONDITION

GRAPH 7.3.2 FEED RATE VS CHIP THICKNESS IN MQL CONDITION

33
7.4 EFFECT OF MQL ON SURFACE ROUGHNESS

Surface finish of the work piece materials was measured on an optical measuring
microscope. 70 x 50 light section measuring equipment made by Japan. The surface
roughness was taken perpendicular to the turning direction. In this work an average surface
roughness (Ra) values were measured by taking average of the three readings. Figure and
shows the surface roughness for dry and MQL machining of HS316-L steel turning. It clearly
reveals that increase in surface roughness with the increase in the feed rate and also the
decreases in surface roughness with the increase in cutting speed. The reduction in surface
roughness was observed to be maximum of 10 to 14% in minimum quantity of lubrication
technique. This could be due to the reduction in the metal cutting forces. The decrease in
surface roughness due to 10% boric acid with SAE 40 base oil can be attributed due to
interest lubricating properties even at high temperatures. The lubricating action of the boric
acid with SAE 40 base oil reduces frictional forces at the chip-tool-interface and tool-work
piece interface. This decreases the temperatures at the cutting zone and results in lesser tool
wear, thus resulting in surface quality improvement.

34
TABLE 7.4.1 FEED RATE VS SURFACE ROUGHNESS IN DRY CONDITION

S.NO

TABLE 7.4.2 FEED RATE VS SURFACE ROUGHNESS IN MQL CONDITION

S.NO

9
35
GRAPH 7.4.1 FEED RATE VS SURFACE ROUGHNESS IN DRY CONDITION

GRAPH 7.4.2 FEED RATE VS SURFACE ROUGHNESS IN MQL CONDITION

36
7.5 EFFECT OF MQL ON CHIP BREAKING

In addition to tool life improvement, minimum quantity lubricant machining eases the
chip breaking. Figure shows the chips obtained in dry cuttings and fig shows the chip
breaking improvement for HS316-Lsteel with MQL cutting by cooling chips, which is known
to be very difficult in chip handling. Minimum quantity lubricant has more financial benefits
than dry machining. The benefits resulting from environmental improvements and from
reducing employees health problems can be highly significant. 10% boric acid with SAE base
oil lubricant does not possess a pathetic clinical history. They are relatively free from hazards
inherent with the use of flooded cutting fluids. These benefits may be the main incentive for
industry to select minimum quantity of lubrication in metal cutting. Because minimum
quantity lubricant metal cutting is a near to dry machining and clean machining processes, the
chips are not contaminated to cutting oil, minimize recycling cost. In addition less tool wear,
higher cutting speed and less BUE improve the work surface finish.

37
 FIG 7.5.1: PHOTOGRAPH OF CHIP BREAKING IN DRY CUTTINGS WITH ACTUAL
PARAMETERS

FIG 7.5.2 PHOTOGRAPH OF CHIP BREAKING IMPROVEMENT IN MQL CUTTING WITH

ACTUAL PARAMETERS

38
 CHAPTER-8

COST ESTIMATION

8.1 COST ESTIMATION

TABLE 8.1.1 COST ESTIMATION

S.NO

9
 CHAPTER – 9

COMPARISON

9.1 COMPARISON OF MQL AND NORMAL COOLANT OIL

FIG 9.1.1 COMPARISION OF MQL AND NORMAL COOLANT OIL

The comprasion of minimum quantity liquid and coolant oil the various
factors we considered in the project.
 Economic factor
 Envirnomental factor

 Machining factor

ECONOMIC FACTOR

Excessive Temprature In The Total Or Work Surface Can Ruin The

Temper Of Both Soften Either To The Point Of Uselessness Or Failure, Burn Adjacent
Material , Create Un Wanted Thermal Expansion Or Lead To Unwanted Chemical Reations
Such As Oxidation.

40
ENVIRNOMENTAL FACTOR

In Envirnomental Factor We Consider The Oil Properties They Use

Mineral Oil .Is Produce From Petroleum Waste Is Not Good For Labour Skin And
Envirnomental Its Affect The Skin Of Labour.some chemical reaction not good for labour
health.

MACHINING FACTOR

Various kind of cutting fluids which include oils oil water emulssions
pastes gets aerools and air or other gases the may be mde from petroleum distillaties, animal
fats , plant oils .
Tool life and work piece life is improved in the MQL oil.smoothing
process can be obtained .

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 CHAPTER-10

ADVANTAGES

10.1 ADVANTAGES OF MINIMUM QUANTITY LIQUID

10.1.1 FINANCIAL ADVANTAGES

 Due to the omission of supply and disposal of coolant,

 High savings are possible.

 After optimization of processes, a higher tool life can be expected.

 Optimized processes reduce the machine cycle time up to 30 %.

 Purchase, warehousing and transportation costs as well as disposal costs of the

 Coolant will be reduced considerably.

 There will be no expenditures for control and care of coolant.

 Depending on the application, extensive follow-up processes for cleaning

 Washing of the Work pieces will be reduced or can be completely eliminated.

 Compared to wet metal chips, which are treated like hazardous waste, dry metal

 Chips can be sold as recycling material.

10.1.2 ECOLOGICAL ADVANTAGES

 No used emulsions will accumulate.

 Accidents due to large quantities of leaking coolant are avoided.

 Due to a dry machine, the risk of accidents at work are reduced.

 Airway or skin diseases caused by coolants can be avoided.

42
 CHAPTER – 11

APPLICATIONS

11.1 APPLICATIONS OF MQL

Minimum Quantity Lubrication (MQL) and Near Dry Metalworking (NDMW)

is the most recent and quickly advancing technology in metalworking fluid systems.

This technology was originally developed in the aerospace industry because the
scale of the work amplified the negative attributes of the traditional flood type coolant and
surface quality requirements made dry machining not possible.

Most of the early development was based around circular sawing, milling, and
drilling non-ferrous metals. AMCOL became an early adopter and developer of this new
technology.

AMCOL has worked continuously to improve the application technology to be

flexible enough to expand to less traditional markets. We have also researched and developed
new chemistries to allow expansion of these methods to many high pressure, high heat, and
high strength metal fabrication processes.

Today, AMCOL services a highly diverse customer base and offers MQL and
NDMW to manufacturers previously unable to adopt this new advancement.

11.2 TODAY’S APPLICATIONS

Processes – Circular sawing, shearing, milling, drilling, roll forming,

band sawing, lathe cutting, CNC profiling, turning, and stamping

Metals – Aluminium, steel, HSLA, Super Alloys, tool steel, copper, and brass

Shapes – Extrusions, rods, bars, sheets, plates, billets, stampings, tubes, and
roll formed shapes

This method of lubrication can apply anywhere you would like to maximize tool
life without the traditional coolant mess.

43
 CHAPTER-12

CONCLUSIONS

12.1 CONCLUSIONS

MQL is a technique that could reduce many cutting problems coming from high
consumptions of lubricant, like high machining costs or environmental and worker health problems.
Therefore, it is important to know all advantages and limits of this technique. The present work shows
how MQL can be advantageous when cutting normalized 100Cr6 steel. The results from experimental
tests and EDS microanalysis are summarized here. Lubricating the rake surface of a tip by the MQL
technique does not produce evident wear reduction. Tool life time of a tip used in dry cutting
conditions is similar to that of a tip lubricated by MQL on the rake. Lubricating the flank surface of a
tip by the MQL technique reduces the tool wear and increases the tool life. Traces of lubricant
compounds have been found on the worn surfaces only when MQL has been applied on the flank
surface. In conclusion, MQL gives some advantages during the turning operation, but it presents some
limits due to the difficulty of lubricant reaching the cutting surface.

44
 CHAPTER-13

REFERENCES

13.1 REFERENCES

 Minimal quantity lubrication in turning: Effect on tool wear A. Attanasio ∗, M.Gelfi,

C.Giardini, C.Remino Department of Mechanical Engineering, University of Brescia, Via
Branze 38, 25123 Brescia, Italy Received 28 September 2004; received in revised form 15
April 2005; accepted 16 April 2005 Available online 15 July 2005

 Optimization of Minimum Quantity Lubrication Parameters in High Speed

Turning of Superalloy Inconel 718 for Sustainable Development
 D. G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan
 Machining Using Minimum Quantity Lubrication: A Technology for Sustainability

Nourredine Boubekri, Ph.D. Professor Department of Engineering Technology

University of North Texas Discovery Park Vasim Shaikh Graduate student
Department of Engineering Technology University of North Texas Discovery Park

 Investigation of turning of AISI H 13 with applying minimum quanitity of

lubricant Department of Mechanical Engineering, Dehaghan Branch, Islamic Azad
University, Dehaghan, Isfahan, Iran 1Mostafahadi1980@yahoo.com

 Effects of minimum quantity lubrication on turning AISI 9310 alloy steel

using MQL oilbased cutting fluid M.M.A. Khana,∗, M.A.H. Mithua, N.R. Dharb a
Department of Industrial and Production Engineering, Shahjalal University of Science
and Technology, Sylhet, Bangladesh b Department of Industrial and Production
Engineering, Bangladesh University of Engineering and Technology, Dhaka,
Bangladesh

 Application of Minimum Quantity Cooling Lubrication Technology in Cutting

Processes Uwe Heisel; Marcel Lutz (Stuttgart) Dieter Spath; Robert Wassmer; Ulrich
Walter (Karlsmhe)

 Experimental Investigation Of Minimum Quantity Lubricants In Alloy Steel

Turning *L B Abhang And M. Hameedullah Mechanical Engineering Department,
Aligarh Muslim University, Aligarh

45