preperation of metal working fluid from castor oil & performance analysis by taguchi method

PREPERATION OF METAL WORKING FLUID FROM CASTOR OIL & PERFORMANCE ANALYSIS BY TAGUCHI METHOD

Guided by: MR.S.Sankara kumarSubmitted by:

P.Mani kandanG.Bala singh

S.KrishnanM.Alagappapandian

Upload by: ALAGAPPAPANDIAN M

INTRODUCTIONVegetable oils are viable and renewable source of environmentally benign oils.

The increased need for renewable and biodegradable lubricants can be traced to stronger environmental concerns and growing regulations over contaminations and pollution.

Here we are using castor oil based cutting fluids and tested by taguchi method.

The Taguchi method was developed by Dr. Genichi Taguchi of Japan who maintained that variation.

Taguchi method is used to Identify the best parameters for machining operation. Taguchi method is used to produce high quality product at low cost.

OBJECTIVESOur ultimate aim of our project is to increase the performance of machining

operation and at the same time to produce more eco-friendly metal working fluid.

Preparation of vegetable oil based metal working fluid by using emulsion method.

The prepared metal working fluid is tested by taguchi method.

In taguchi method by varying different parameter to find out the best quality product.

METAL WORKING FLUIDS

Cutting fluids are used to reduce the negative effects of the heat and friction on both tool and work piece.

The cutting fluids produce three positive effects in the process: i. Heat removal elimination, ii. Lubrication on the chip–tool interfaceiii. Chip removal

cutting fluids are classified into four categories:i. cutting oils, ii. soluble oils (emulsified oils, emulsions),iii. synthetic (chemical) fluids,iv. semi-synthetic (semi- chemical) fluids.

PREPARATION OF CUTTING FLUID

Base oil + Emulsifier + Other additives

Base oil- vegetable oil (castor oil )

Other additives

Emulsifier agent – sodium hydroxide

Neutralization agents Corrosion and rust inhibitorsLubricating additives (antiwear and EP additives) Biocidies and fungicides Foam inhibitors

PROCEDURECOMPOSITION:-

Base oil – 40%Water - 35%Additives - 15%Emulsifier - 5-15%

Initially castor oil is added to water for two minutes.Then add all substances (emulsifier, additives) , they are mixed together for 15 minutes followed by stirring process. Now the emulsion will occurs.After emulsion occurs it will undergoes to stability test.This will done by keeping prepared solution for 24hours then it wants to be stable.

The percentage of emulsifier agent is depend on stability of cutting fluid.

Fig.1 sample preparation of castor oil based metal working fluid

EMULSION

A. Two immiscible liquids, not yet emulsifiedB. An emulsion of Phase II dispersed in Phase IC. The unstable emulsion progressively separatesD. The surfactant (purple outline around particles) positions itself on the interfaces between Phase II and Phase I, stabilizing the emulsion

An emulsion is a mixture of two or more liquids that are normally immiscible (no mixable or unbendable). Emulsions are part of a more general class of two-phase systems of matter called colloids.

What is Taguchi method?The goal of the Taguchi method is to produce high quality product at low cost to the

manufacturer and to society from variability in manufacturing processes.

Taguchi developed a method for designing experiments to investigate how different parameters affect the mean and variance of a process performance characteristic that defines how well the process is functioning.

The experimental design proposed by Taguchi involves using orthogonal arrays to organize the parameters affecting the process and the levels at which they should be varies.

Instead of having to test all possible combinations like the factorial design, the Taguchi method tests pairs of combinations.

Here we are using L9 orthogonal method to find out good machining performance parameters (cutting speed, feed rate, depth of cut, Lubricant ).

L9 Orthogonal Array

Here, P1,P2,P3,P4 parameters

EFFECT OF MACHINING PARAMETERS IN PERFORMANCE

FISH BONE DIAGRAM

MODEL TABLBULATIONExperiment Cutting

Speed(rpm)Feed(mm/rev)

Depth of cut(mm)

lubricant Surface roughness

1 1 1 1 1

2 1 2 2 2

3 1 3 3 3

4 2 1 2 3

5 2 2 3 1

6 2 3 1 2

7 3 1 3 2

8 3 2 1 3

9 3 3 2 1

TESTING• Here we are considering carbide bit as cutting tool and stainless steel

(304ss) as work piece. • From considering above table the machining process is done for constant

time. The initial and final weight of tool and work piece is calculated before and after machining respectively.

• The tool weight is measure to calculate tool wear. And work piece weight is measure to calculate metal removal rate (MRR).

CONCULSIONThus the optimization method by taguchi for turning process by considering various parameters has good quality of good surface roughness.Also the more eco-friendly vegetable oil based metal working fluid is prepared.

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