Term Paper Review

on
MEC-104

TOPIC-Importance of cutting fluids

and lubrication in different
manufacturing process.

Name-Raushan Sudhanshu
Sec-B4902
Roll-B4902B35
Regd-10901326

Submitted To:-Mr.Rakesh Kumar

How to do it – production drawings
The third SolidWorks tutorial explains how to create a drawing from a SolidWorks
part. Use the
sheet format on my website. Most of the work is done for you by SolidWorks –
cross sections and
detailed views are quick to produce, but you will need to re-order and add and
delete dimensions to
make your drawing clear. Use you British Standard to make sure everything
meets BS 8888.
I have included the beginnings of a production drawing overleaf. I have used a
cross-section, but
further detailed views might be necessary, e.g. a detail of the crankcase stud
holes/grooves would
help in interpreting the drawing. My dimensioning is not complete. SolidWorks will
automatically
produce very messy dimensions, using all those you have specified in your
SolidWorks model. While
you might have needed a dimension in your model, it may not be necessary on
the drawing – consult
the section on dimensioning in your British Standard carefully.
Cutting fluid
Introduction
Thin-wall milling of aluminum using a water-based cutting fluid on the milling
cutter.
Cutting fluids are various fluids that are used in machining to cool and lubricate
the cutting tool. There are various kinds of cutting fluids, which include oils, oil-
water emulsions, pastes, gels, and mists. They may be made from petroleum
distillates, animal fats, plant oils, or other raw ingredients. Depending on context
and on which type of cutting fluid is being considered, it may be referred to as
cutting fluid, cutting oil, cutting compound, coolant, or lubricant.
Every kind of machining (e.g., turning, boring, drilling, milling, broaching,
grinding, sawing, shaping, planing, reaming, tapping) can potentially benefit from
one kind of cutting fluid or another, depending on workpiece material. (Cast iron
and brass are usually machined dry. Interrupted cuts such as milling with carbide
cutters are usually recommended to be used dry due to damage to the cutters
caused by thermoshock.)

Mechanisms of action
Cooling
Metal cutting operations involve generation of heat due to friction between the
tool and the pieces and due to energy lost deforming the material. The
surrounding air alone is a rather poor coolant for the cutting tool, because the
rate of heat transfer is low. Ambient-air cooling is adequate for light cuts with
periods of rest in between, such as are typical in maintenance, repair and
operations (MRO) work or hobbyist contexts. However, for heavy cuts and
constant use, such as in production work, more heat is produced per time period
than ambient-air cooling can remove. It is not acceptable to introduce long idle
periods into the cycle time to allow the air-cooling of the tool to "catch up" when
the heat-removal can instead be accomplished with a flood of liquid, which can
"keep up" with the heat generation.

Lubrication at the tool-chip interface

Besides cooling, cutting fluids also aid the cutting process by lubricating the
interface between the tool's cutting edge and the chip. By preventing friction at
this interface, some of the heat generation is prevented. This lubrication also
helps prevent the chip from being welded onto the tool, which interferes with
subsequent cutting.
EP additives are often added to cutting fluids.

Delivery methods
Every conceivable method of applying cutting fluid (e.g., flooding, spraying,
dripping, misting, brushing) can be used, with the best choice depending on the
application and the equipment available. For many metalcutting applications the
ideal would be high-pressure, high-volume pumping to force a stream of fluid
directly into the tool-chip interface, with walls around the machine to contain the
splatter and a sump to catch, filter, and recirculate the fluid. This type of system
is commonly employed, especially in manufacturing. It is often not a practical
option for MRO or hobbyist metalcutting, where smaller, simpler machine tools
are used. Fortunately it is also not necessary in those applications, where heavy
cuts, aggressive speeds and feeds, and constant, all-day cutting are not vital.

Types of cutting fluid

Liquids
There are generally three types of liquids: mineral, semi-synthetic, and synthetic.
Semi-synthetic and synthetic cutting fluids try to blend the best properties of oil
into the best properties of water. They basically achieve this by allowing oil to
emulsify into water. Some of these properties are: rust inhibition, tolerance of a
wide range of water hardness (maintain pH stability around 9 to 10), ability to
work with many metals, resist thermal breakdown, and environmental safety.[1]
Water is a great conductor of heat but has drawbacks as a cutting fluid. It boils
easily, promotes rusting of machine parts, and does not lubricate well. Therefore,
other ingredients are necessary to create an optimal cutting fluid.
Mineral coolants, which are petroleum-based, began in the late 1800s. They vary
from the thick, dark, sulfur-rich cutting oils used in heavy industry to light, clear
oils.
Semi-synthetic coolants are an emulsion or microemulsion of water with mineral
oil. They began in the 1930s. A typical CNC usually uses emulsified coolant, which
consists of a small amount of oil emulsified into a larger amount of water through
the use of a detergent.
Synthetic coolants originated in the late 1950s and are usually water-based.
A hand-held refractometer is used to determine the mix ratio (also called
strength) of water soluble coolants to verify effectiveness. Numerous other test
equipment are used to determine such things as acidity, and amount of
conductivity.

Pastes or gels
Cutting fluid may also take the form of a paste or gel when used for some
applications, in particular hand operations such as drilling and tapping.

Mists
Some cutting fluids are used in mist (aerosol) form, although breathing such a
lubricant in mist form is a severe and immediate health hazard.
Safety
Cutting fluids have been associated with skin rashes, dermatitis, esophagitis, lung
disease, and cancer. These problems result from either toxicity or bacterial or
fungal contamination.
Metalworking fluids often contain substances such as biocides, corrosion
inhibitors, metal fines, tramp oils, and biological contaminants. Inhalation of
cutting fluid aerosols may cause irritation of the throat, nose, and lungs and has
been associated with chronic bronchitis, asthma, hypersensitivity pneumonitis
(HP), and worsening of pre-existing respiratory problems. Skin exposure may
result from touching contaminated surfaces, handling parts and equipment,
splashing fluids, and aerosol mist settling on the skin. Skin contact with cutting
fluids may cause allergic contact dermatitis, irritant contact dermatitis, and
occupational ("oil") acne.[2]
Safer formulations provide a natural resistance to tramp oils allowing improved
filtration separation without removing the base additive package. Ventilation,
splash guards on machines, and personal protective equipment can mitigate
hazards related to cutting fluids.[3]
Bacterial growth is predominant in semi-synthetic and synthetic fluids. Tramp oil
along with human hair or skin oil are some of the debris during cutting which
accumulates and forms a layer on the top of the liquid, anaerobic bacteria
proliferate due to a number of factors. An early sign of the need for replacement
is the "Monday-morning smell" (due to lack of usage from Friday to Monday).
Antiseptics are sometimes added to the fluid to kill bacteria. Such use must be
balanced against whether the antiseptics will harm the cutting performance,
workers' health, or the environment. Maintaining as low a fluid temperature as
practical will slow the growth of microorganisms.[3]

Lubricants
Introduction
A lubricant (sometimes referred to as "lube") is a substance (often a liquid)
introduced between two moving surfaces to reduce the friction between them,
improving efficiency and reducing wear. They may also have the function of
dissolving or transporting foreign particles and of distributing heat.
One of the single largest applications for lubricants, in the form of motor oil, is to
protect the in motor vehicles and powered equipment.
Typically internal combustion engineslubricants contain 90% base oil (most often
petroleum fractions, called mineral oils) and less than 10% additives. Vegetable
oils or synthetic liquids such as hydrogenated polyolefins, esters, silicones,
fluorocarbons and many others are sometimes used as base oils. Additives deliver
reduced friction and wear, increased viscosity, improved viscosity index,
resistance to corrosion and oxidation, aging or contamination, etc.
Lubricants such as 2-cycle oil are also added to some fuels. Sulfur impurities in
fuels also provide some lubrication properties, which has to be taken in account
when switching to a low-sulfur diesel; biodiesel is a popular diesel fuel additive
providing additional lubricity.
Non-liquid lubricants include grease, powders (dry graphite, PTFE, Molybdenum
disulfide, tungsten disulfide, etc.), teflon tape used in plumbing, air cushion and
others. Dry lubricants such as graphite, molybdenum disulfide and tungsten
disulfide also offer lubrication at temperatures (up to 350 °C) higher than liquid
and oil-based lubricants are able to operate. Limited interest has been shown in
low friction properties of compacted oxide glaze layers formed at several hundred
degrees Celsius in metallic sliding systems, however, practical use is still many
years away due to their physically unstable nature.
Another approach to reducing friction and wear is to use bearings such as ball
bearings, roller bearings or air bearings, which in turn require internal lubrication
themselves, or to use sound, in the case of acoustic lubrication.
In addition to industrial applications, lubricants are used for many other purposes.
Other uses include bio-medical applications (e.g. lubricants for artificial joints) and
the use of personal lubricant for sexual purposes.

Purpose
Lubricants perform the following key functions.
• Keep moving parts apart
• Reduce friction
• Transfer heat
• Carry away contaminants & debris
• Transmit power
• Protect against wear
• Prevent corrosion
• Seal for gasses
• Stop the risk of smoke and fire of objects

Types of lubricants
• Gas
• Liquid including emulsions and suspensions
• Solid
• Greases
• Adhesive

Gaseous lubricants
Gaseous lubricants have a much lower viscosity and higher compressibility
compared to liquid lubricants, but the fluid-film principles apply analogeous to
gases. Some examples for gaseous lubricants are air (used in fluid bearings),
technical gases, steam or liquid-metal vapours.
Liquid lubricants
Liquid lubricants may be characterized in many different ways. One of the most
common ways is by the type of base oil used. Following are the most common
types.
• Lanolin (wool grease, natural water repellant)
• Water
• Mineral oils
• Vegetable (natural oil)
• Synthetic oils
• Other liquids

Lanolin
A natural water repellent, lanolin is derived from sheep wool grease, and is an
alternative to the more common petro-chemical based lubricants. This lubricant is
also a corrosion inhibitor, protecting against rust, salts, and acids.

Water
Water can be used on its own, or as a major component in combination with one
of the other base oils. Commonly used in engineering processes, such as milling
and lathe turning.

Mineral oil
This term is used to encompass lubricating base oil derived from crude oil. The
American Petroleum Institute (API) designates several types of lubricant base oil

Grease
The term grease is used to describe a number of semisolid lubricants possessing
a higher initial viscosity than oil. Although the word grease is also used to
describe rendered fat of animals, in the context of lubricants, it typically applies to
a material consisting of a calcium, sodium or lithium soap base emulsified with
mineral or vegetable oil

Adhesive
Nitrocellulose adhesive outside a tube
For the band, see Adhesive (band).
"Glue" redirects here. For other uses, see Glue (disambiguation).
Adhesive or glue is a compound in a liquid or semi-liquid state that adheres or
bonds items together. Adhesives may come from either natural or synthetic
sources. Some modern adhesives are extremely strong, and are becoming
increasingly important in modern construction and industry. The types of
materials that can be bonded using adhesives are virtually limitless, but they are
especially useful for bonding thin materials. Adhesives usually require a controlled
temperature to cure or set. They can be electrically and thermally conductive or
nonconductive

Environmental impact
Old, used cutting fluid must be disposed of when it is fetid or when it is chemically
degraded and has lost its performance. As with used motor oil or other wastes, its
impact on the environment should be mitigated. Legislation and regulation specify
how this mitigation should be achieved. Enforcement is the most challenging
aspect. Modern cutting fluid disposal may involve techniques such as
ultrafiltration using polymeric or ceramic membranes which concentrates the
suspended and emulsified oil phase