Shroff S.R.

Rotary Institute of
Chemical Technology

Experimental study of Minimum Quantity Lubrication method

during machining of difficult to cut materials.

Group ID: 112781

Enrollment No. Name of the Student

140990119034 Patel Nitin

180993119002 Barad Akash
2020-2021
180993119006 Mourya Umesh

Mr. Samir Jariwala, Subject: Project-I (2170001)

Guide by
Professor/Assistant Professor

Department of Mechanical Engineering

 Contents
Sr. No. Topic Slide No.
01 Introduction 03
02 Literature Survey 14
03 Aim & Objectives 19
04 Procedure/Analysis 20
05 Competition Work chart 21
06 References 23

2
 Introduction
⮚ Introduction to Manufacturing:
Manufacturing is step by step process through which raw materials
are converted into a final product. Manufacturing process begins
with the product design, material specification from which the
product is made. These materials are then modified though
manufacturing processes to become the final product.
⮚ Types of manufacturing:

3
 Types of manufacturing

Casting: In this manufacturing process the raw material is heated

at very high temperature to convert it into molten state. Then it is
poured into a mould and allowed to cool down and after it gets
cooled the mould is removed and we get desired shaped final
product. Casting is itself a moulding type of manufacturing process.

4
 Types of manufacturing

Machining: Machining is one of the most essential processes in

the manufacturing industry which involves a controlled elimination
of material from the substrate by using a cutting tool. In the
machining operation plastic deformation of the work piece material
and friction between tool chip and tool-work piece interface, lots of
energy abounding is converted into heat. Different techniques were
evolved for the effective elimination of this heat generated from the
surrounding area of the machining. One of those techniques
evolves the used of coolant in the form of fluid during the process.

5
 Types of manufacturing

Joining: At some point we need to put multiple parts together to

make single piece. In joining process we use welding, soldering and
brazing to apply heat to join metals. Pieces can also be joined by
using fasteners and adhesive bonding.

6
 Types of manufacturing

Shearing and Forming: Shearing uses cutting blades to

make straight cuts into a metal piece. Shearing process is also
known as die cutting. Punching is shearing process. In metal
forming process we heat metal below its melting point and apply
hammering to move materials into desired shape.

7
 What are hard materials?

• Hardness can be defined as the ability of material to resist

deformation, indentation, or penetration by means such as
abrasion, drilling, scratching. Hardness value more than 45HRC
considered as hard material.
• Examples of hard materials are steel, tungsten carbide,
ceramics, titanium alloys, nickel alloys etc.
• Applications of hard materials are breaking jaws in jaw crusher,
ceramic for implants and dental prostheses, grinding tools,
bearings etc.

8
 What is hard machining?

• Hard machining is latest technology that is defined as a machining

operation using tool with geometrically defined cutting edge, of a work
piece that has hardness value typically in 45-70 HRC range.
• The material of cutting tool should have the following characteristics:
a. Harder than the work piece
b. Stable at high temperature
c. Excellent resistance to wear and thermal stresses
d. Excellent impact resistance
e. Chemically inert to the work piece material
• Super hard tool materials divided into two categories: Cubic Boron
Nitride (CBN) and Polycrystalline diamond (PCD).
• All cutting tools have finite working life which is termed as
“perishable”, it is not advisable to use worn and dull tools until they
break due to safety hazards
9
 Minimum quantity lubrication (MQL) method:

MQL is the process of applying minute amounts of high quality

lubricant directly to the cutting tool/work piece interface instead of
using traditional flood coolant.
▪The excellent lubricity of a MQL lubricant means the majority of heat
from friction is directly transmitted to the chip and exits the interface
as chip evacuated. This lubrication and transfer of heat keeps the
cutting tool much cooler and reduce tool wear.
▪ The friction and heat in the interface vaporize small amount of
lubricant and leave cutting tool, parts, equipments and floor dry and
clean.
▪The swarf or chip from cutting with MQL are almost dry and can
recycle without performing any cleaning operation.
▪There is no disposal requirement and no extra equipment is
10 necessary for fluid reclamation.
 Components of MQL:
Air filter , Solenoid valve , Reservoir , Pump , Nozzle
Advantages of MQL:
▪ Reduce fluid consumption in significant manner as compared to
flood lubrication method.
▪Safer fluids
▪Reduce health hazards
▪Faster machining
▪Longer tool life
▪Lower disposal cost
▪Clean ship environment
▪Reduce maintenance

11
 Lubricants ( Vegetable Oil )

▪ Metal cutting generates heat due to friction and plastic

deformation of chips.
▪ The surrounding air has low thermal conductivity so it is
unable to provide cooling to tool and work piece.
▪ Rise in temperature of tool and work piece can affect the
surface finish of work piece and tool life. To overcome this
problem we use lubricant.
▪ Biggest disadvantage of lubricant is disposal after its use and
the lubricants are also harmful to the health of operator.
▪ To solve this problem we will be going to use vegetable oils as
lubricant instead of grease.

12
 Properties of different vegetable oil

Properties Coconut Olive oil Palm oil Rapeseed oil Soyabeam oil Sunflower oil
oil

Smoke point (oC) 232 216 235 204 232 232

Flash point(oC) 270 315 314 317 317 316

Fire point(oC) 329 342 341 344 342 341

Density 916 918 882.5 911.4 920.3 919.6

(kg/m³)

Dynamic Viscosity(cSt) 29 40.1 50.63 34.55 40.49 41.67

Thermal 0.321 0.16 0.171 0.154 0.154 0.161

conductivity(W/mK)

13
 Literature Survey
NO. Paper Title & Year Working Area Outcomes/ Remarks
   
The effect of machining The MQL method could decrease
1. Performance evaluation of
conditins on the tool wear and the tool wear and surface
vegetable oil based nano surface roughness was roughness.
investigated lathe machine of  
cutting fluids in machining
AISI 1040 steel
Optimum cutting conditions are
using Grey Relational
found to be 40m/min and
Analysis-A step towards 0.14mm/rev for reduction in
cutting forces, cutting
sustainable manufacturing
temperatures and tool wear.
(2018) Surface roughness is observed to
be minimum at a speed of
100m/min and feed rate of 0.14
mm/rev.

The objective of this work is to MQL has been successfully

2. On machining of Ti-6Al-4V
investigate the effects of multi demonstrated as an acceptable
using multi-walled carbon walled carbon nanotubes coolant strategy; however, its
(MWCNTs) cutting fluid during
nanotubes-based nano-fluid The nano-cutting fluids
cutting of Ti-6Al-4V
significant improvements on the
under minimum quantity
cutting performance,
lubrication (2018) understanding the MQL nano-
fluid mechanisms is highly
14 important
 Literature Survey
No. Paper Title & Year Working Area Outcomes/ Remarks
   
Novel uses of SiO2 The hard turning test was carried The minimum tool wear is obtained
3.
nano-lubrication system out to investigate tool wear with a 0.5%wt nanoparticle
in hard turning process reduction and surface quality concentration in the mineral oil, 2 bar
of hardened steel improvement of machined air stream pressure and a 60 nozzle
AISI4140 for less tool hardened orientation angle.
wear, surface roughness  
steel AISI4140 when using SiO2
and oil
nano-lubrication. Surface roughness can be enhanced
consumption
with a 0.5 wt% concentration in the
mineral oil, less air stream pressure
and a 30 nozzle orientation angle.

Analysis of Lubrication   The MQL & MQCL method could

4.
Strategies for Analysis of Lubrication Strategies decrease the tool wear and surface
Sustainable Machining for Titanium Ti-6Al-4V alloy roughness
during Turning of  
Titanium Ti-6Al-4V
vegetable oil is low tool wear
alloy
achieved at higher feed and
speed.

15
 Literature Survey
No. Paper Title & Year Working Area Outcomes/ Remarks
   

Applying Minimum Quantity The experiments were The MQL method could
5.
Lubrication (MQL) Method conducted under dry, MQL decrease the tool wear and
on Milling of Martensitic with vegetable cutting fluid, surface roughness.
Stainless Steel by Using and MQL with nanofluid.
Nano Mos2 Reinforced Nano MoS2 particles were Besides, an increment of the
Vegetable Cutting Fluid added to the vegetable MQL flow rate caused a
(2015) cutting fluid reduction in both the tool wear
and surface roughness

Optimization of Minimum The Taguchi method was In MQL conditions, the water-
6.
Quantity Lubricant applied to find the optimal soluble oil lubricant, the 50 mL/h
Conditions and Cutting values of MQL condition in the fluid flow and the 3 kg/cm2
Parameters in Hard Milling hard milling of AISI H13 with pressures provided the best results
of AISI H13 Steel (2016) consideration of reduced for surface roughness in hard-
surface roughness milling of SKD 61

16
 Literature Survey
No. Paper Title & Year Working Area Outcomes/ Remarks
   

Effects of Minimum Quantity Effects of minimum quantity A continuous MQL supply showed
7.
Lubrication (MQL) in lubrication (MQL) using better results in terms of tool life
machining processes using conventional and nanofluid rather than an interrupted MQL
conventional and nanofluid based cutting fluids. supply system.
based cutting fluids: A
comprehensive review (2016) MQL milling showed an excellent
cutting performance under high
speed end milling

Effectiveness of vegetable oil The turning operation of AISI Flash and Fire points, specific
8.
based nanofluids as 1040 steel workpiece under density, thermal conductivity,
potential cutting fluids in different types of nanofluid specific heat and heat 
turning AISI 1040 steel(2016) lubricant environm-ents. transfer coefficients are observed to
increase with increase in npi for all
nanofluids.

Absorbance is found to increase

with increase in npi up to 0.5 % and
slightly decreased with more
increase in npi

17
 Literature Survey
No. Paper Title & Year Working Area Outcomes/ Remarks
   

Application of Nanofluids in This research investigated the The preliminary study of MQL
9.
Minimum Quantity wheel wear and tribological grinding showed that it could
Lubrication Grinding(2008) characteristics in wet, dry, and significantly reduce the grinding
minimum quantity lubrication temperature compared to dry
(MQL). grinding
However, there is no significant
difference in grinding temperature
when using nanofluids

Optimization of machining The experiments are conducted It is also found that the evolutionary
10.
parameters and cutting fluids based on response surface techniques are more effective for
during nano-fluid based methodology and a combined determining the optimal machining
minimum quantity lubrication objective function using the parameters of titanium (grade-2)
turning of titanium alloy by output parameters was alloy considering NFMQL
using evolutionary techniques generated. conditions.
Also it is observed from the
microstructure analysis that, while
using graphite based nano-fluids
finer laminar structure are produced
as compared to other two nano-
fluids
18
 Aim & Objectives
Aim: study of Minimum Quantity Lubrication method during
machining of difficult to cut materials.
Objectives:
Our main work is to select proper Machining parameters, Nano-
Lubricant and Lubrication method to achieve the following
objectives:
▪ To reduce cooling lubricant requirement.
▪ To reduce tool wear and increase tool life.
▪ To reduce in cooling lubricant disposal cost and cost of disposal
of scrap contaminated with cooling lubricant.
▪ To reduce hazards to the operator’s health and to those who
exposed directly to lubricants.
▪ To reduce environmental pollution due to improper disposal of
lubricants.
19
 Procedure
1. Study of part literature.
2. Stirring and mixing of nano particles in the lubricant
vegetable oil.
3. Study of various characteristics of lubricant like viscosity, fire
point , flash point etc.
4. Experiment design based in DOE( Taguchi method)
5. Actual experiment perform in lathe machine with MQL
method.
6. Analysis of results in terms of cutting forces and surface
integrity
7. Adaptability of nano based lubricant in machining

20
 Work Plan
Month
No. Activity
Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Nov-20 Dec-20 Jan-21 Feb-21 Mar-21

1 Project
Allocation
2 Project
Definition
3 Introduction to
Project
4 Literature
Survey
5 Nanoparticle
Selection
6 Mixing
Process
7 Analysis of
Nanolubricant

8 Application on
actual
machining
9 Generating
Characteristics
curve
21
 References
Research Papers:
▪ ALPER UYSALA, FURKAN DEMIRENA, ERHAN ALTAN. “APPLYING MINIMUM
QUANTITY LUBRICATION (MQL) METHOD ON MILLING OF MARTENSITIC
STAINLESS STEEL BY USING NANO MOS2 REINFORCED VEGETABLE
CUTTING FLUID” PROCEDIA, ELSEVIER - SOCIAL AND BEHAVIORAL
SCIENCESALPER

▪ APPLIED SCIENCES “OPTIMIZATION OF MINIMUM QUANTITY LUBRICANT

CONDITIONS AND CUTTING PARAMETERS IN HARD MILLING OF AISI H13
STEEL” APPLIED SCIENCES ANUJ KUMAR SHARMA A, ARUN KUMAR TIWARI
B , AMIT RAI DIXIT.

▪ “EFFECTS OF MINIMUM QUANTITY LUBRICATION (MQL) IN MACHINING

PROCESSES USING CONVENTIONAL AND NANOFLUID BASED CUTTING
FLUIDS” ELSEVIER JOURNAL OF CLEANER PRODUCTION

▪ PADMINI, P. VAMSI KRISHNA, G. KRISHNA MOHANA RAO “EFFECTIVENESS

OF VEGETABLE OIL BASED NANOFLUIDS AS POTENTIAL CUTTING FLUIDS IN
TURNING AISI 1040 STEEL” ELSEVIER, TRIBOLOGY INTERNATIONAL
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 ▪ CLEANER PRODUCTION OF PERFORMANCE EVALUATION OF VEGETABLE OIL BASED
NANO CUTTING FLUIDS IN MACHINING USING GREY RELATIONAL ANALYSIS-A STEP
TOWARDS SUSTAINABLE MANUFACTURING WRITTEN BYPADMINI RAPETI, VAMSI
KRISHNA PASAM, KRISHNA MOHANA RAO GURRAM, RUKMINI SRIKANT REVURU

▪ SPRINGRVERLAG LONDON ON MACHINING OF TI-6AL-4V USING MULTI-WALLED

CARBON NANOTUBES-BASED NANO-FLUID UNDER MINIMUM QUANTITY
LUBRICATION WRITTEN BY H. HEGAB, H. A. KISHAWY , M. H. GADALLAH, U.UMER, I.
DEIAB

▪ ELSEVIER JOURNAL OF CLEANER PRODUCTION OF NOVEL USES OF SIO2 NANO-

LUBRICATION SYSTEM IN HARD TURNING PROCESS OF HARDENED STEEL AISI4140
FOR LESS TOOL WEAR, SURFACE ROUGHNESS AND OIL CONSUMPTION WRITTEN BY
MOHD SAYUTI, AHMED A.D. SARHAN, FAHEEM SALEM

▪ ELSEVIER LTD. ANALYSIS OF LUBRICATION STRATEGIES FOR SUSTAINABLE

MACHINING DURING TURNING OF TITANIUM TI-6AL-4V ALLOY WRITTEN BY IBRAHIM
DEIAB, SYED WAQAR RAZA, SALMAN PERVAIZ

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 Shroff S.R. Rotary Institute of
Chemical Technology
Questions and Suggestions are
Welcome

Thank You
Subject: Project-I (2170001)

Department of Mechanical Engineering