DESIGN AND FABRICATION OF MINIMAL CUTTING

FLUID APPARATUS FOR HARD TURNING

GROUP NAME:J
GUIDED BY: GROUP MEMBERS
Mr SARFARAZ AHAMED K ADHEEB HUSSAIN
ASSISTANT PROFESSOR MOHAMED SHAFEEQ SHIHABUDHEEN
MUHAMMED ALI SHIHAB P
VISHNU T
IJAS AHAMED KP
MOHAMMED SUHAIL K
 OBJECTIVE

 To study about conventional Hard Turning methods

 To design an apparatus to reduce the use of cutting fluid during hard
turning
 To analyze various characteristics parameters affecting the hard
turning
 To fabricate apparatus that provides the best parameters for the hard
turning and obtain good surface finished material with minimal
cutting fluid application
 INTRODUCTION

 Conventional hard turning requires very large quantities of cutting fluid

 Storage and procurement of cutting fluid involves expenses
 The disposal of cutting fluid is also another problem
 Utilization of cutting fluid posses severe environmental problem
 There are syringe and environmental regulations such as
OSHA[Occupational Safety and Health Administration] that regulates the
amount of fluid vapour permissible in the shaft environmental
 In this circumstances pure dry turning is an alternative as it needs no cutting
fluid at all
 But pure dry turning requires ultra hard cutting tools which are very costly
and needs extremely rigid machine tools
 Turning with minimal fluid application is a viable alternative in this regard
 In this technique, very small quantities of cutting fluid(1-2ml/min)is applied with high
velocities at critical zones as a pulsating jet
 Since the amount of fluid used is very less, the technique is free from environmental
pollution in shop floor
 It is reported that surface finish par with conventional wet turning is possible during
turning of hardened AISI 4340 steel
 In the present investigation it is proposed to evaluate the suitability of this technique for
turning of OHNS-steel(widely used in die making industry)
METHODOLOGY
 LITERATURE REVIEW

 T.Brockoff,A.Walter
 Shilpa Sahare,Prashant Kamble,Divya N.Dubey says

 It is apparent that MQL system poses many advantages over flood

coolant system
 However they also require some modification of machine tools for
obtaining best performance put of them
 when flood coolant system not present machine tools should be
equipped with tool removal system
 Wang et al says

 The tool plays a major role during the machining process

 During hybrid machining of the Inconel 718 WG-300 ceramic tool

inserts produce better surface finish,longer tool life and lower
cutting forces compared with conventional machining
 Mazurkiewics et al says

 High pressure jet of soluble oil if applied at the chip-tool interface,

could reduce cutting temperature and improve tool life to some
extent
 This is by decreasing heat and cutting force generated
 Su et al says

 Application of air cooling with minimal quantity lubrication

techniques resulted in longer tool life compared to dry and minimum
quantity lubrication
 Machado and Wallbank says

 Surface finish, chip thickness and force variation are all beneficially
affected by minimal cutting fluid application with fast flowing air

 Cutting force, feed force were reduced when lubricant was applied
under low cutting speed and high feed rate
 Rahman et al says

 The application of minimum quantity lubrication in milling

applications of ASSAB 718 HH steels and found that the cutting
force was reduced for MQL as compared with dry turning and flood
coolant turning ,especially at low cutting speed of 75 m/min
 DESIGN AND COMPONENTS

1. P6 fuel pump
2. Infinitely variable electrical drive
3. Mixing chamber
4. Cutting fluid supply line
5. Pressure testing equipment
6. Dynamometer
CALCULATIONS
COST ESTIMATION
EXPECTED OUTCOME
 ADVANTAGES

 Reduction of cutting fluid up to about 2ml/min

 Decreases tool-chip contact and hence cutting force
 Good surface finish
 Flooding effect reduced drastically
 Reduces storage, transportation of large quantity of cutting fluid
 Easy chip removal and disposability
 No major modification done on cutting apparatus
 Reduces environmental pollution
 DISADVATAGES

 Initial cost
 Requirement of special formulized cutting fluid
 Maintenance cost
 REFERNECE
 [1] E.O. Ezugwu, A.R. Machado, I.R. Pashby, J. Wallbank, The effect of high
pressure supply when machining a heat resistant nickel based super alloy, Journal
of the Society of Tribologists and Lubrication Engineers 47 (1991) 31–37.
 [2] R. Alaxender, A.S. Varadarajan, P.K. Philip, Hard turning with minimum
cutting fluid—a viable green alternative on the shop floor, in: Proceedings of the
18th All India Manufacturing Technology Design and Research Conference
December 21–23, Kharagpur, India, 1998, vol. 1, pp. 83–187.
 [3] A.S Varadarajan., P.K. Philip, B. Ramamoorthy, Neural network assisted
performance prediction in hard turning with minimal quantities of cooling
lubricants, in: Proceedings of the 14th International Conference, CAD/CAM,
Robotics and Factories of the Future, December 1–3, Coimbatore, India, 1998,
pp. 654–658.
[4] A.S. Varadarajan, P.K. Philip, B. Ramamoorthy, investigations on hard
turning with minimal pulsed jet of cutting fluid, in: Proceedings of the
International seminar on Manufacturing Technology beyond 2000 Bangalore,
India November 17–19, 1999, pp. 173–179.
 [5] A.S. Varadarajan., P.K. Philip, B. Ramamoorthy, Optimization of operating
parameters for the cutting performance during Hard Turning with minimal
cutting fluid, in: Proceedings of the International Conference on Intelligent
Flexible Autonomous Manufacturing systems January, 2000, pp. 717–725.

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THANK YOU