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1. INVESTIGATION OF EFFECTS OF CUTTING FLUID
ON TOOL LIFE, AND WORKING ENVIRONMENT
.
A PROJECT REPORT - PHASE I
Submitted by
MOHANRAJ M 511721410008
in partial fulfillment for the award of the degree of
MASTER OF ENGINEERING
IN
MANUFACTURING ENGINEERING
PALLAVAN COLLEGE OF ENGINEERING
ANNA UNIVERSITY, CHENNAI 600 025
MARCH 2023

2. ANNA UNIVERSITY, CHENNAI
BONAFIDE CERTIFICATE
Certified that this project report “INVESTIGATION OF EFFECTS OF CUTTING FLUID ON TOOL LIFE, AND
WORKINGENVIRONMENT” is the bonafide work of, MOHANRAJ M (511721410008)who carried out the project
work under my supervision.
SIGNATURE SIGNATURE
Mr. V.GOPAL M.E., Mr. V.GOPAL M.E.,
HEAD OF THE DEPARTMENT SUPERVISOR
ASSOCIATE PROFESSER
Dept. of Mechanical Engineering Dept. of Mechanical
Engineering
PALLAVAN COLLEGE OF ENGINEERING PALLAVAN COLLEGE OF
ENGINEERING
Submitted for the Anna university project VIVA VOCE exam is held on ………….
Internal Examiner External Examiner

3. ABSTRACT
 A Manufacturing world which concentrated on design, product development, production rate
and profit now has to focus on tool life, human welfare and environmental issues due to the
fulfillment of statutory requirements and quality aspects. This paved way for the birth of the
several approaches for risk assessment and control of occupational hazards.
 In the metal working industry, one of the most important issues is the heat generated in
cutting process. High temperature in metal cutting degrades the tool life, surface integrity,
size accuracy and machining efficiency. Main objective can be achieved by maintaining the
important cutting fluid parameters and operating procedures during the machining process.
 Detailed studies have revealed that the exposure to cutting fluid has harmful effects on
human health due to inhalation and skin contacts. Also sever contamination impacts on the
environment in the form of air and land pollutions resulting from vapor released during
machining process and disposal of used oil. This project focused on the quality improvements
of cutting fluid and the standard practices of usage during the machining operation mainly
attributed on reduction in cutting zone temperature and minimize its adverse effects on
human health and environment.

4. INTRODUCTION
 Cutting fluid In the metal working industry, one of the most important issues is the heat
generated in cutting process. High temperature in metal cutting degrades the tool life,
surface integrity, size accuracy and machining efficiency. Historically, cutting fluids have
been used extensively in metal cutting operations for the last 200 years. In the beginning,
cutting fluids consisted of simple oils applied with brushes to lubricate and cool the machine
tool. Occasionally, lard, animal fat or whale oil was added to improve the oil's lubricity. As
cutting operations became more severe, cutting fluid formulations became more complex.
Today's cutting fluids are special blends of chemical additives, lubricants and water
formulated to meet the performance demands of the metalworking industry. There are now
several types of cutting fluids on the market, the most common of which can be broadly
categorized as cutting oils or water-miscible fluids. Water-miscible fluids, including soluble
oils, synthetics and semi synthetics, are now used in approximately 80 to 90 percent of all
applications. Although straight cutting oils are less popular than they were in the past, they
are still the fluid of choice for certain metalworking applications. Cutting fluids play a
significant role in machining operations and impact shop productivity, tool life and quality of
work. With time and use, fluids degrade in quality and eventually require disposal once their
efficiency is lost.

5. Project objective
 The primary objective of this project is to maintain fluid quality and
performance through administration, monitoring, maintenance and recycling
practices. This allows machine shops to make the most cost-effective use of
their fluid. It is also the best pollution prevention technology available for
standardization. Overall, project provides a means to: Increased tool life.
Consistently manufacture quality products Minimise the adverse effects on
human health. Operate in a more environmentally sound manner. Improve
productivity and reduce costs. Provide a healthier and safer work
environment for employees

6. Project methodology

7. LITERATURE REVIEW
 [1] Vikram Kumara Ch R., Ramamoorthy, B. (2007) explains the main objective of using
cutting fluids in machining operations is the reduction of temperature in the cutting region to
increase tool life. The cutting fluids are used in machining operations in order to (i) Reduce
friction at the tool-chip and tool work- piece interfaces, (ii) Cool both chip and tool, and (iii)
Remove chip. Furthermore, they have a strong effect on the shearing mechanisms and,
consequently, on the work-part surface finish and tool wear.
 [2] Yahya Isik (2010) work deals with experimental investigation in the role of cutting fluids
on cutting temperature, cutting forces, tool wears, and surface roughness value in machining
AISI-1050 steel at industrial speed-feed condition by CVD coated carbide TiC+AI2O3+TiN insert
as compared to completely dry machining. The results of the present work indicated that
cutting fluid did not show a significant improvement on surface roughness particularly when
cutting tests with 0.8 mm nose radius were considered. In fact, the roughness similarly
deteriorated under wet machining in some of tests.
 CVD coated carbide TiC+AI2O3+TiN cutting tool performed better during wet machining
mode. The results of the present work indicate substantial reduction in tool wear, which
enhanced the tool life; this may be mainly attributed to reduction in cutting zone
temperature and favorable change in the chip-tool interaction. 5 The cutting fluid enabled in
reducing the main cutting force due to improved and intimate chip-tool interaction. It
provided more efficient chip removal and heat reduction.

8. LITERATURE REVIEW
 [3] Dr. Pratesh Jayaswal, Nidhi Gupta (2012) has done analytical and experimental
vibration analyses for a lathe system to detect the effect of cutting parameters
such as cutting speed, depth of cut and feed rate on machining variables is
evaluated. Transient dynamic analysis showed that the vibration velocity level
increases as the cutting speed, depth of cut and feed rate increases The optimal
condition for working on centre lathe machine is cutting speed of 230-350 rpm,
feed rate of 0.1-0.2 mm/rev and depth of cut up to 1 mm so it is not advisable to
wok on high cutting speed, feed rate and more depth of cut because it directly
affect the tool life it also shows that vibrations at bearing and in tangential
direction are highly occurred comparatively at tool post and in axial direction.
 [4] Howard Cohen and Eugene M. White (2006) work has stated the occupational
exposure limit (OEL), recommended exposure limit (REL) for metalworking fluids
(MWF) to prevent respiratory disorders associated with these industrial lubricants.
The REL of 0.4 mg/m3 (as a time-weighted average for up to 10 hours) was for the
fraction of aerosol corresponding to deposition in the thoracic region of the lungs.

9. PROJECT PROCESS
 Cutting tool Tool is a device in which energy is expanded to produce jobs of
desired size, shape and surface finish by removing excess material from the blank
in the form of chips.
 3.1.1. Tool Life Tool wear can present a significant limitation to machining
productivity. Taylor first defined an empirical relationship between tool life and
cutting speed, referred to as the Taylor tool life equation: v T n = C Where v is the
cutting speed in m/min, T is the tool life in minutes, and n and C are constants
which depend on the tool-workpiece combination. The constant C is defined as the
cutting speed required obtaining a tool life of 1 minute.
 Tool life can be defined as the time required reaching a predetermined flank wear
width, FWW, although other wear features (such as crater depth) may also be
applied. According to the Taylor tool life equation, tool life is dependent on
cutting speed (or spindle speed for a selected tool diameter in milling) and their
relationship is quantified empirically using a power law exponent, n, and a
constant, C, which are tool-workpiece dependent.

10. Control and diagnostics of cutting fluids
 Diagnostics of cutting fluids can be classified according to the method and control
periodicity into the following categories.
 No control – emulsion is used until there are no problems connected to the
quality of work pieces, health problems of maintenance or damage to the
machine.
 Laboratory control - Simple operation without monitoring equipment –
consideration of design, smell of fluid and look of surface which is washed with
cutting fluid operation control.
 - Manual processing with monitoring equipment (e.g. manual optical
refractometer, pH records, test for determination of water and nitrite hardness)
 Real time control. - Monitoring systems without feedback (modification of
parameters is manual) - Monitoring systems with feedback (modification of
parameters is automated)

12. Proposed Cutting fluid monitoring
system

14. EXPERIMENTAL SETUP
 4.1. Proposed work equipments The proposed work equipments can be
classified into two ways. First is the primary equipments machine, tool, work
piece and cutting fluid set up and the secondary instruments which are used
for the cutting fluid quality monitoring and controlling.

15. Primary equipment details
 Specification : CNC Lathe , MAZAK – QT 150
 (Quick Turn 150mm Max. Diameter)
 Machine Tool Specification : RH Turning tool
 Tungsten Carbide CNMG Work piece material : Alloy steel (20 Mn Cr 5 steel)
 Cutting Fluid Used : Water Soluble – Castrol
 NC Programming software : MAZATROL
 The primary equipment is the CNC Lathe machine

16. Proposed work cutting fluid circuit

17. CONCLUSION
 Cutting fluids play an important role in engineering operation, and therefore it is very
important to use fluids with good properties, conditions and to known the changes which
proceed in the system and the causes of their formation. Monitoring system which is
described in this proposed work is simple to use and allows to reduce changes of fluids
properties and improve production with reduction of cutting fluids waste.
 Merits of the proposed system
 The main aim was to design the proposed on-line monitoring system, which differs from
the existing ones are the following.
 The access to measurement method of the cutting fluids
 concentration.
 The concentration measurement is simpler.
 Increased the tool life.
 Improve the productivity.
 Improve Safety and minimize environment pollution.
 Reduce the effect of human health impacts.
 Costs are lower

18. CONCLUSION
 Proposed work status The following proposed work has been completed as
phase – 1
 Objective (selection)
 Collection of information
 Method for conduct of machining on sample work piece.
 Study the method and propose a procedure to use the method. Yet to be
completed as phase – 2
 Conducting the machining operation.
 Analyzing the experiment details Conclusion.
 Scope for future work

19. REFFERENCE
 Vikram Kumara Ch R., Ramamoorthy, B.(2007) ‘Performance of coated tools
during hard turning under minimum fluid application’, Journal of Materials
Processing Technology, vol. 185, p. 210-216.
 2. Yahya Isik (2010), ‘An Experimental Investigation on Effect of Cutting Fluids
in Turning with Coated Carbides Tool’, Strojniški vestnik - Journal of
Mechanical Engineering , vol. 56, p. 1-3.
 3. Dr. Pratesh Jayaswal, Nidhi Gupta (2012), ‘An investigation on tool
condition monitoring’, International Journal of Engineering Science and
Technology (IJEST), Vol. 4 No.08, p. 3858-3865

20. REFFERENCE
 4. Howard Cohen and Eugene M. White (2006), ‘Metalworking Fluid Mist
Occupational Exposure Limits: A Discussion of Alternative Methods’, Journal of
Occupational and Environmental Hygiene, Vol. 3, p. 501– 507.
 5. Oğuz Çolak, (2012)‘Investigation on Machining Performance of Inconel 718
under High Pressure Cooling Conditions’, Strojniški vestnik - Journal of
Mechanical engineering, Vol. 58(2012)11, p. 683-690.
 6. K.Kadirgama, M.M.Noor1, K.A. Abou-El- Hossein H.H.Habeeb, M.M.
Rahman, B.Mohamad, R.A. Bakar (2010), ‘Effect of Dry Cutting on Force and
Tool Life when Machining Aerospace Material’, World Academy of Science,
Engineering and Technology, Vol. 47 ( 2010), p. 452-456

21. THANKING YOU