Project Batch No.

Evaluation of cutting forces and surface roughness on turning and

drilling AA6061 using vegetable oils as cutting fluid

SYNOPSIS

Preamble:
In the machining process, cutting fluids are used to improve its efficiency, tool life and surface finish.
Presently, petroleum based oils are being used as cutting fluids. The over exploitation of petroleum
products will lead to occupational hazards and environmental pollution. The introduction of
environmental legislation series by OSHA and other International regulation authorities, made the
manufacturing sector to reduce the consumption of mineral oil based metal working fluids. There is a
huge potential for utilizing vegetable oils as cutting fluids in manufacturing sector[1]. Vegetable oils
cannot be used directly, because of their lower oxidative stability[2]. However, modified and formulated
oils can be used as a substitute for the petroleum based cutting fluids.
Vegetable oils consists of glycerol molecules with 3 long chain fatty acids attached via ester linkages
having polar fatty acid chains, which provide high strength lubricant films that interact strongly with
metallic surfaces, reducing both friction and wear[3].
AA6061, an Aluminium alloy containing magnesium & silicon as its major alloying elements[4], is
being extensively used because of its better strength, formability, weldability, and corrosion resistance
compared to other aluminium alloys[5]. It is used in the construction of aircraft structures such as wings,
fuselages, pulleys, brackets, ducts, wave guides and complex valve bodies of hydraulic control systems,
construction of ship, wheel hubs, bumpers, Engine blocks, Cylinder heads, Pistons, Camera lens
mountings, bridge decks, Bike frames etc.

Literature survey:
 Abdalla.et.al.[6] described the application of methodologies for the formulation of sustainable
neat-oil metal removal fluids.
 Abdalla.H.S.et.al.[7] describes the development of methodologies for the formulation of novel
sustainable neat-oil MWF. 4 formulations for target applications (stainless steel & aerospace-
grade titanium alloys) were developed & suitable benchmark fluids were identified.
 Peter Raynor.et.al.[8] formulated 5 metal working fluid emulsions from soybean oil & concluded
that the air-oxidised soybean oil was the most promising candidate.
  Salete Martins Alves.et.al.[9] formulated a castor oil based cutting fluid for grinding process.
The chemical analysis based on 1992(OECD),1997,showed that the new fluid found to be non-
toxic and biodegradable.
 Jacob John.et.al.[10] described a method for the formulation of vegetable oil-in-water emulsions.
Soyabean oil was modified with sulphur, ozone and oxygen and emulsions were prepared.
 Singh.et.al.[1] utilized few non edible oils like neem, karanja and ricebran, to develop eco-
friendly MWF.
 DeChiffre and Belluco[11] studied the performance of cutting fluids for machining operations
for austenitic stainless steel. The results revealed that the cutting force under vegetable oils and
esters modes were low compared to mineral oils and the tool life was escalated.

Present work:
Here, two non edible vegetable oils, Jatropha and Karanja, are chosen for lubrication. These vegetable
oils are modified by esterification and esterification followed by epoxidation. Physicochemical tests are
conducted to confirm the extent of formulation. The formulated Jatropha and Karanja oils are used for
turning and drilling AA6061. Mist lubrication, using the specified cutting fluids (which are in the form
of straight oils), is employed. Parameters such as surface roughness and cutting forces are chosen for the
study. The cutting forces are measured using Lathe tool Dynamometers and surface roughness by
Tallysurf.
Further, the test results are compared with the results obtained under mineral oil. Pollution and
environmental health aspects have become immensely important public issues now and biodegradable
vegetable oils offer the best choice in formulating the environment-friendly lubricants.

References:
[1] Singh AK, et al. Metal working fluids from vegetable fluids. J Synth Lubr 2006;l23:167–76.
[2] Fox NJ, Stachowiak GW. Vegetable oil based lubricants–A review of oxidation. Tribol Int 2007;40:1035–46.
[3] Matthew TS, Nader S, Bigyan A, Lambert AD. Influence of fatty acid composition on the tribological performance of
two vegetable-based lubricants. J Synth Lubr 2007;24:101–10.
[4] Kelly J.F., Cotterell M.G. Minimal lubrication machining of aluminium alloys
[5] Joseph P V, Deepak Saxena, Sharma D K. Study of some non-edible vegetable oils of Indian origin for lubricant
application. Journal of Synthetic Lubrication,2007,8;327-47.
[6] H S Abdalla and S Patel The performance and oxidation stability of sustainable metalworking fluid derived from
vegetable extracts,Department of Product and Spatial Design, De Montfort University, Leicester, UK.
[7] H. S. Abdalla . W. Baines . G. McIntyre . C. Slade,Department of Environmental and Occupational Health, Development
of novel sustainable neat-oil metal working fluids for stainless steel and titanium alloy machining 2006
[8] Peter c. Raynor, Seung Won Kim and Mrinal Bhattacharya, Mist Generation from Metalworking Fluids Formulated
Using Vegetable Oils.
[9] Salete Martins Alves, Joao Fernando Gomes de Oliveira Development of new cutting fluid for grinding process adjusting
mechanical performance and environmental impact University of Sao Paulo, Brazil.
[10] Jacob J. Emulsions containing vegetable oils for cutting fluid, application. Colloids Surf A: Physicochem Eng Aspects
2004;237:141–50.
[11] De Chiffre L. Investigations of cutting fluid performance using different machining operations. Lubr Eng 2002:22–8.

USN Signature Name

4MC07ME035 Krishnakishor S. Gour
4MC07ME037 Madhukar Mallya B.
4MC07ME084 Sadashivaiah T.G.
4MC07ME086 Sanket Naik

Signature of Guide:

Signature of Project co-ordinator: