Study on Surface Roughness and Chip Formation During Milling Operation of Mild Steel Using Vegetable Based Oil as a Lubricant

The purpose of this project research is focused on the study of surface roughness and chip formation during milling operation of Mild Steel using vegetable based oil as a lubricant. Experimental set up designed by using milling machine. Taguchi Method of Orthogonal Array with factorial design of experiments used to analysis the response. Surface roughness and chip formation predicting models was developed by using experimental data and analysis of the present lubricant and vegetables based oil. In the development of predictive models, cutting parameters of cutting velocity, feed rate, and depth of cut were considered as model variables. Further, the Analysis of Variance (ANOVA) technique was used to analyze the influence of process parameters and their interaction during machining. From the analysis, it is observed that cutting speed is the most significant factor on the surface roughness followed by depth of cut and feed rate. While Sunflower Oil gives the lowest surface roughness by setting of the best combination parameter. Besides, the most influenced factor that contributes to larger chip formation is depth of cut. Even the lower cutting speed and smaller feed rate had been used, the size still become larger when it comes to the increasing of depth of cut. Index Term — Chip Formation, Lubricants, Machining, Surface Roughness, Taguchi Method of Orthogonal Array I. INTR ODU C TIO N Surface roughness determines how a real object interacts with its environment. Rough surfaces usually wear more quickly and have high friction coefficient than smooth surfaces. Roughness is often a good predictor of the performance of mechanical components, since irregularities in the surface may form nucleation sites for cracks or corrosion [1]. Although roughness is usually undesirable, it is difficult and expensive to control in manufacturing. Decreasing the roughness of surface will usually increase its metal cutting costs exponentially. Surface quality is an important requirement for many machine parts. The purpose of the metal cutting process is not The objectives of this study include; to study the effect of using vegetables based oil as lubricant on surface roughness and chip formation during milling operation of Mild Steel and to analyze This work was supported in the part by University Malaysia Perlis under STG Grant No: 9001-00386. S. A. Adam, N. A. Shuaib, and M. R. M. Hafiezal are with the School of Manufacturing Engineering, University Malaysia Perlis, Pauh Putra Campus, Jalan Arau-Changlun, 02600 Arau, Perlis, Malaysia (phone: 604-9885035; fax: 604-9885034; e-mail: [email protected]). S. N. Suhaili is with MDC Precast Industries Sdn. Bhd., Mukim Rasa, Selangor, Malaysia (e-mail: [email protected]) the result using Design of Experiments (DOE) method; Taguchi Method (Orthogonal Array). Importance of this study is to focus on environmental effects. Due to growing environmental concerns, vegetable oils are finding their way into lubricants for industrial and transportation applications [4]. Since the application of conventional cutting fluids creates some environmental problems like environmental pollution, water pollution, and biological problems to operators, the solution need to be analyze to solve the problem. Vegetables oils indeed offer significant environmental benefits with respect to resource renewability, biodegradability, as well as providing satisfactory performance in a wide array of applications. So, this paper highlights the effect of vegetable oils as a lubricant to the surface roughness and chip formation by manipulating several parameters. II. SCOPES OF RESEARCH WORK This study focused on the effect of vegetable oil as lubricant towards surface roughness and chip formation during milling operation. Vegetable oil such as sunflower oil and soybean oil will be applied on mild steel metal. Then, analysis using Design of Experiment (DOE) was done by using Taguchi Method (Orthogonal Array) and Analysis of Variance (ANOVA ). III. SELECTION OF VEGETABLE OIL One potential alternative is the use of environmentally compatible or environmental friendly oils that are produced from vegetables. To achieve this classification, oil must be nontoxic and must biodegrade rapidly if spilled [2]. Vegetable based oils are triglycerides or natural esters that come from agricultural crops. These oils are natural products and therefore their chemical composition varies somewhat from one crop to another. They have some undesirable characteristics. Vegetable oils have many good natural properties including good lubricity, good resistance to shear, a high flash point, and a high viscosity index [3]. The information contained is based on background investigations, literature searches, and consultations with technical specialists. Based on this and limited field observations, vegetable based oils are an attractive. The cleanliness and non-toxic characteristics of the vegetable based oils make them worth trying [5]. Sunflower Oil and Soybean Oil has been chosen as lubricants in this research according to their properties. A recent investigation performed by Alauddin et al. [7] has revealed that when the cutting speed is increased, International Journal of Engineering & Technology IJET-IJENS Vol:13 No:01 2