Identification of Sources of Leakages of Hydraulic & Neat Cutting Oil on 16T Broaching m/c (RG+SL Broaching machines)

1. MEDICAPS INSTITUTE OF TECHNOLOGY AND
MANAGEMENT
INDUSTRIAL TRAINING AT
AVTECH Ltd.
Submitted To Submitted By
Dr. K.K. Gupta Shivam Pandey
Head of Mechanical Dept. (0812ME111094)

2. AIM
Identification of Sources of
Leakages of Hydraulic & Neat
Cutting Oil on 16T Broaching m/c
(RG+SL Broaching machines)

3. The Broaching Machine – A Brief
Introduction
• Broaching is a method of removing metal by pushing or
pulling a cutting tool known as broach which cuts in fixed
path.
• Surfaces finished by broaching may be flat or contoured
and may be either internal or external.
• Broaching is generally limited to the removal of about 6mm
of stock or less.
• The machine which performs broaching is known as the
broaching machine.
• The broaching machine is probably the simplest of all
machine tools. It consist of a work holding fixture, a
broaching tool, a tool drive mechanism, and a suitable
frame.

4. • It consist of one or more rams depending upon the
production requirement.
• Dual ram models are arranged so that when one ram
is on the cutting stroke, the other is on the return
stroke.
• The return stroke is performed quickly to gain time,
which is used to unload and load the machine.
• Broaching machine usually pull or push the broach
through, or past a workpiece that is held in a fixture.
• Most broaching machines are hydraulically operated
to secure a smooth & uniform action.

5. The Broaching machine
Cutting Oil
Pipe
Base
Plate

6. Broaches

7. Sources Which Are Identified
• The cutting oil gets sprinkled from the working
area to the back side of the machine.
• Oil leakages were found at the joints of the
hydraulic pipes.
• Oil goes out with the chips via conveyor in the
chip trolley.
• Cutting oil adheres to the material and goes
into the bin along with the material.

8. Source no. 1
The cutting oil gets sprinkled from the working area to
the back side of the machine.

9. Reason of Spillage
• When the machine is switched ON and when the
broach starts cutting the material, lots of cutting oil
is used in order to cool the material and the broach.
• The cutting oil is also used for the lubricating and
cleaning purposes.
• This cutting oil comes out of a pipe and is made to
spill on the broach and the material.
• This oil coming out of the pipe gathers in the working
area and slowly goes into the oil tank.

10. • During cutting, the chips also goes into the oil
tank with the oil.
• This sometimes blocks the oil passage and
therefore the oil starts pouring out of the cutting
area and out of the machine.
• During cutting the area where the material is kept
is filled with the chips and it needs to be cleaned
after every cutting cycle.
• During this cleaning, the cutting oil splash out of
the machine.
• When the broach cuts the material, it creates
some vibrations in the machine and due to this
vibrations, some oil splash out of the machine.

11. Actions taken in order to prevent the
spillage
• A metal guard is made in the shape shown in
the figure.
• This metal guard is placed in front of the
operator and behind the broach.
• When the cutting oil gets sprinkled, the metal
guard stops it from going out of the working
area and thus the oil goes straight to the
cutting oil tank.

12. Metal Guard

13. Source no. 2
Oil leakages were found at the joints of the hydraulic
pipes.

14. Reason of Spillage
• While the machine is working it undergoes a
lots of vibrations due to the cutting of the
material by the broach. Due to this vibrations
the joints of the hydraulic pipes gets loose and
thus oil starts leaking from this joints.

21. Actions taken in order to prevent the
spillage
• At first we cleaned all the hydraulic pipes
properly with the help of cotton.
• Now we start working on the machine.
• If there are any leakages in the pipes it will be
easily observed now.
• By this way we indentified the leakages.
• All the joints where there were leakages are
tightened and thus leakages were prevented.
• Some minor leakages can be prevented by
applying a sealant at the joints.

22. Source no. 3
Oil goes out with the chips via conveyor in the chip
trolley.

24. Reason of Spillage
• While the machine is cutting the material, the
chips also goes into the cutting oil tank along with
the cutting oil.
• This chips needs to be carried out of the cutting
oil tank in order to prevent contamination.
• This chips are carried out of the oil tank via a
magnetic conveyor through which the chips goes
into the chip trolley
• But while the chips are coming out of the oil tank,
some amount of oil also gets out of the tank and
goes into the chip trolley along with the chips

25. Actions taken in order to prevent the
spillage
• Since the oil coming out of the tank with the
chips cannot be stopped, therefore we needed
to do something in the chip trolley itself.
• A filter can be provided over the chip trolley
so that the oil can go through the filter in the
trolley which further can be poured out into
the oil tank.

26. Source no. 4
Cutting oil adheres to the material and goes into the bin
along with the material.

27. Reason of Spillage
• While the machine is working we provide a lot
of cutting oil to the cutter(broach) and
material.
• This cutting oil after the process is done
adheres to the material.
• This material when carried out of the machine
contains some amount of oil adhered to its
surface.

28. Actions taken in order to prevent the
spillage
• The material after cutting should be hanged
onto some hinged pin so that the adhered oil
on the material gets drained.
• The material after cutting should be placed
somewhere and should be kept there for a
particular amount of time to get drained.

29. Disadvantages of leakages
• Due to the leakages the oil is wasted and hence it
increases the cost of production.
• Leaked oil mix with the chips and dust and thus
contaminate the area.
• Leaked oil on the ground can make the surface
slippery.
• Mixture of oil and dust affects the working of
machine and its accessories.
• Leakage of oil will require more cleaning of the
machine and the area and thus increasing the
cost of maintenance.

30. Conclusion
Oil Consumption (in Lit.)
Monthly Oil Consumption Report - 2013~14
Oil Consumption in Ltrs.
Apr May Jun Jul Aug Sep Oct Nov Dec
Monthly Plan
40 100 100 90 20 40 40 40 80 80
0 0 0 0 0 0 0 0 0 0
190 320 200 70 140 40 80 120 180 300
40 0 100 40 120 40 25 80 80 195
0 0 0 0 0 0 0 0 0 0
190 180 200 140 120 180 400 240 370 240
EP-68 is the Hydraulic Oil
ILO BROACH NO. 11 is the Cutting Oil

31. Conclusion
• After performing various activities defined
above ,we have identified every possible
source of consumption of hyd. & cutting oil in
the broaching machines. This sources are now
prevented by applying various actions
discussed above. By preventing all this
sources, we will reduce the consumption of
the cutting and the hydraulic oil upto 20~25%
and finally reduce the cost of the production.

32. Thank you