ACKNOWLEDGEMENT

We would like to acknowledge some people without whom this project wouldn’t have been
completed. Sachin sir who always stood for us and motivated us to do more throughout the project.
Maya mam for their guidance in the project. Panchal sir and Kathkede sir for supervising the actual
experiment.

INTRODUCTION

In metal cutting operation there are majorly 3 zones of heat generated mainly due to friction
and plastic deformation of material. Primary (A-B), Tool chip interface (A-C) and tertiary (A-D) as
shown the figure. The metal cuts after plastic deformation the heat generated is very large. This heat
needs to be extracted from the machining region else thermal deformation of tool will take place and
the quality of product will deteriorate. For extraction of the heat generated cutting fluids have been
used traditionally. This experiment deals with the use of cutting fluid and its effect on surface quality
of the work piece. Due to capillary action the cutting fluid penetrates in the machining region and heat
extraction is carried out.

EXPERIMENTAL WORK

The experiment was conducted on LATHE machine for turning operation, on mild steel as a
work material and tungsten carbide (CERATIZIT TNMA 160408 EN CTICK 110) as cutting tool material.
3 Work pieces were cut out of equal diameter of 26 mm keeping depth of cut constant throughout
the operation of 1 mm. Auto feed was implied. Surface morphology was measured using Dial Indicator
(BAKER least count 10 microns). Cutting fluid used was Castrol cutting oil with 1:18 ratio. Following
are the results of the experiment conducted.
OBSERVATION TABLE

SR. No. Rpm (rev/min) Feed (mm/rev) Coolant Discharge Tolerance (µm)
(lph)

1 315 0.033 0 40
500 43.9 5
775 105.8 4
2 315 0.05 0 50
500 17.6 20
775 45 15
3 315 0.1 0 30
500 120 25
775 243 20
RESULTS
CONCLUSION

1) From result we can draw conclusion that every time for dry machining the tolerance is quite
high in order of 20-40 µm and as we use cutting fluids the tolerance drops down in range of
10 microns.
2) The optimum tolerance out of the three results would be for higher cutting speed (775) and
low feed (0.033) with coolant discharge of 45 lph.
3) As feed increases even though use of coolant has provided better surface roughness but at
higher feeds it has nearly no impact on surface quality.

FUTURE SCOPE

1) Variation in cutting fluid mixture and its effect of surface quality.

2) Optimum discharge rate could be possible.