Mimec 2013 Sultan

Examining the Effect of Various Vegetable Oil-Based Cutting Fluids on Surface Integrity in

Drilling Steel : A Review by

Ahmad Zubair Sultan

Safian Sharif & Denni Kurniawan

Content

Objectives

Introduction

Recent Findings & Remarks

Concluding Remark

OBJECTIVES

This paper gives an overview of the influence of VO-CF on surface integrity of steel during the drilling process.

This paper also presented the effect of the different cooling strategies on surface integrity.

Introduction

CF have commonly been viewed as a required addition to high productivity and high quality machining operations.

However the negative effects of the conventional CF have motivated many researchers to look for alternative coolant in replacing the excessive use of mineral and synthetic cutting fluids

Introduction

The advantage of using VO-CF cutting fluid on tool wear and the cutting force have been reported in the literature, but the literature on the effects of its use on the surface finish of the workpiece is still lacking.

Introduction

Surface integrity can be defined as inherent or enhanced condition of a surface produced in machining.

Common defect such as plastic deformation, microcracking, metalurgical transformations, microhardness, tears and laps related to BUE formation, residual stress distribution, etc

IntroductionNumerous studies have been conducted on machining of stainless steel in order to evaluate VO-CF such as• Rapeseed oil [Belluco et al. 2004],

• Coconut oil [Khrisna et al 2010 ; Xavior & Adithan 2009]

• Sunflower oil [Kuram et al.;Ozcelik et al. 2011],• Canola oil [Cetin et al. 2011],

• Palm oil [Sharif et al. 2009]

Recent FindingsKuram et al. (2011)

AISI 304

SCF I = Refined Sunflower ʋ 1.9cp

SCF II = Refined Sunflower ʋ 1.3cp

CSCF I = Crude Sunflower ʋ 1.7cp

CVCF = Commercial Vegetable

CMCF = Commercial Mineral

1.01 µm

2.26 µm

1.03 µm

Recent Findings

1.01 µm

Remark

• An increase in Vc make the drill bit cut better without ploughing, resulting in a drop in Ra value.

• An increase in frate increased the MRR, consequently increasing forces and vibration caused an increase in the Ravalue.

Remark

• Viscosity affects the flow of cutting fluid.

• CF with low viscosity expectedly can reach the t-wp interface more effectively, making chips to be flushed away from the cutting zone and preventing a finished drilled hole surface from becoming scratched [19].

Recent FindingsOzcelik et al. (2011)

VCF I = Vegetbale ʋ 1.5cp

SSCF I = Semi synthetic

MCF = Mineral

1.36 µmVCF II = Vegetable ʋ 1.1cp

1.43 µm

AISI 304

Recent FindingsOzcelik et al. (2011)

1.36 µm

Remark

• VCF-1 produced better surface roughness compared to VCF-2 although the former has higher viscosity.

• This can be attributed to the lubrication ability, in which cutting fluid with low viscosity has poor lubricating capability

• This result hinted that there is a critical cutting fluid viscosity value that can give the best surface roughness out of this workpiece.

Remark

Recent FindingsKilickap et al. (2011)

1.36 µm

AISI 1045

3.04 µm

3.48 µm

MQL tends to result fine surface roughness values compared to dry drilling at the same drilling parameters.

Remark

• The general trend was when cutting speed increases, surface roughness value decreases.

• Contrasting trend that higher cutting speed causes an increase in surface roughness was perhaps due to the increasing tool wear when higher machining speed was employed.

Recent FindingsBrandao et al. (2011)

AISI H13

Remark

• Based on the experiments, it was concluded that cooling technique is of great influence on cylindricity error

• For circularity error, MQL has the worst performance, for instance at the cutting speed.

• It seems that MQL is an effective method to lubricate tool-workpiece interface, but it is not an effective way to cool down cutting zone temperature [23].

Concluding Remarks• It was found that cutting fluid, feed rate, and cutting

speed have significant effect on surface roughness of the steel (AISI 304).

• Surface roughness of austenitic stainless steel being processed by drilling using vegetable oil-based cutting fluids was very fine.

• Considering its advantages and also inconsistence due to viscosity effect on Ra, further research worth pursuing in search of better machining responses using alternative cutting fluids.

End of PresentationsThank You

The authors wish to thank