quaker chemical presentation
TRANSCRIPT
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Comparative Analysis of Ductile Metals vs Compacted Graphite Iron Under Machining Conditions: Final Report
Quaker Chemical, Group 1
-Talal Al-Quassar
-Bethany Ford
-Robert Conrad
-Philip Jaunzemis
-Patrick Reilly
4/16/2013
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Background
The objective of this project is to test the machinabilityof Compacted Graphite Iron (CGI) and two ductilemetals (80-55-06 and 65-45-12) with the use of three
coolants: Quakercool 3750, Quakercool 7020-CG, andQuakercool 7020-CG-2.5
The cutting tools (Kennametal CNMA KCK05) were usedas the test for machinability
Tool wear was measured after a certain number of cutsto examine how well the coolants were working
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Cutting Parameters Ductile 1300 Surface Feet Per Minute
Right Hand Turning Tool
Varying Level Cuts 5 Levels (separated by 2 inches) 1.6 inches in depth per level.
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Ductile 80-55-06 7020 Coolant
5 th Level
50 completed Passes0.714 mm Tool Wear
1st Level
10 completed Passes0.347 mm Tool Wear
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Ductile 80-55-06 7020 2.5 Coolant
5 th Level
50 completed Passes0.861 mm Tool Wear
1st Level
10 completed Passes0.362 mm Tool Wear
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Ductile 80-55-06 3750 Coolant
5 th Level50 completed Passes0.823 mm Tool Wear
1st Level10 completed Passes0.297 mm Tool Wear
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Ductile 65-45-12 3750 Coolant
5 th Level50 completed Passes0.659 mm Tool Wear
2nd Level20 completed Passes0.293 mm Tool Wear
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Ductile 65-45-12 7020 Coolant
5 th Level50 completed Passes0.636 mm Tool Wear
2nd Level20 completed Passes0.278 mm Tool Wear
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Ductile 65-45-12 7020 2.5 Coolant
5 th Level50 completed Passes0.636 mm Tool Wear
2nd Level20 completed Passes0.312 mm Tool Wear
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Cutting Parameters CGI 1300 Surface Feet Per Minute
Right Hand Turning Tool
Scale removal process: Machines off up to 7 inches of the surface. Machines down to 5.645 inches in diameter.
Varying Level Cuts 9 Levels (separated by 0.5 inches) 0.08 inches in depth per level.
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CGI 7020 Coolant
9 th Level
45 completed Passes0.454 mm Tool Wear
4th Level20 completed Passes0.324 mm Tool Wear
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CGI 7020 2.5 Coolant
9 th Level
45 completed Passes0.450 mm Tool Wear
4th Level
20 completed Passes0.335 mm Tool Wear
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CGI 3750 Coolant
9 th Level
45 completed Passes0.480 mm Tool Wear
4th Level
20 completed Passes0.301 mm Tool Wear
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Microstructure
CGI Bulk Material at 20x 65-45-12 Bulk Material at 20x
80-55-06 Bulk material at 20x
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CGI
CGI 7020 Coolant at 20x CGI 7020-2.5 Coolant at 20x
CGI 3750 Coolant at 20x
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80-55-06
7020 Coolant at 50x 3750 Coolant at 50x
7020-2.5 Coolant at 50x
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65-45-12
7020 Coolant at 50x7020-2.5 Coolant at50x
3750 Coolant at 50x
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Tool Wear by Pass80-55-06
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Tool Wear by Pass65-45-12
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Tool Wear by PassCGI
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Analysis
It can be seen from the graphs presented that, althoughtool wear values seem similar, there is a difference inwhich section of the tool curve the values are arrivingat
7020, in terms of the graphs, is wearing the slowestover time since it is in the plateau phase for both the80-55-06 and the CGI
7020-2.5 wears slower for the 65-45-12 than both the3750 and 7020
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Regression Analysis
Regression Equation: y = 0.766 - 0.156x1 - 0.338x2 + 0.0527x3 + 0.0477x4
Predictor Coefficient SE Coefficient T P
Constant 0.76589 0.03218 23.8 0
x1 -0.15567 0.03525 -4.42 0.012
x2 -0.338 0.03525 -9.59 0.001
x3 0.05267 0.03525 1.49 0.21
x4 0.04767 0.03525 1.35 0.248
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Conclusions and Recommendations
It can be seen from the graphs above that Quakercool7020 will have the longest tool life for the 80-55-05ductile iron and CGI
Additionally, the 7020-2.5 will have the longest tool lifebased off of the graph for 65-45-12
This is based on the idea that these lubricants are notyet in the final phase of tool life as compared to theother coolants in their respective categories