Soluble Oil Research Articles

Effect of Coolant Temperature on Surface Finish during Turning of Titanium Alloy Ti6Al4V

High temperature generated and stresses induced as a result of turning of Ti6Al4V results in poor surface finish. The aim of this study was to investigate the effect of coolant temperature on the surface roughness of Ti6Al4V which is a core material used as an implant. A cooling system was developed to reduce the temperature of the coolant (soluble oil) from room temperature to 2oC. Ti6Al4V was turned in dry and cooled (at temperatures 5, 7, 9 and 11 oC) conditions. The experiment was designed using central composite design of (Response surface methodology) Design Expert 11.0 to generate an array and optimize the machining parameters. The machining parameters used were cutting speed, feed rate, depth of cut and coolant temperature. Results analyses show that cutting speed and depth of cut had considerable effect on surface roughness of Ti6Al4V. Surface roughness reduced when coolant temperature was reduced. The results of this study shows that turning Ti6Al4V at a very low cutting temperature will ensure a better surface finish.

Skin Permeation of Solutes from Metalworking Fluids to Build Prediction Models and Test A Partition Theory.

Permeation of chemical solutes through skin can create major health issues. Using the membrane-coated fiber (MCF) as a solid phase membrane extraction (SPME) approach to simulate skin permeation, we obtained partition coefficients for 37 solutes under 90 treatment combinations that could broadly represent formulations that could be associated with occupational skin exposure. These formulations were designed to mimic fluids in the metalworking process, and they are defined in this manuscript using: one of mineral oil, polyethylene glycol-200, soluble oil, synthetic oil, or semi-synthetic oil; at a concentration of 0.05 or 0.5 or 5 percent; with solute concentration of 0.01, 0.05, 0.1, 0.5, 1, or 5 ppm. A single linear free-energy relationship (LFER) model was shown to be inadequate, but extensions that account for experimental conditions provide important improvements in estimating solute partitioning from selected formulations into the MCF. The benefit of the Expanded Nested-Solute-Concentration LFER model over the Expanded Crossed-Factors LFER model is only revealed through a careful leave-one-solute-out cross-validation that properly addresses the existence of replicates to avoid an overly optimistic view of predictive power. Finally, the partition theory that accompanies the MCF approach is thoroughly tested and found to not be supported under complex experimental settings that mimic occupational exposure in the metalworking industry.

The effect of demulsifier on the stability of liquid droplets: A study of micro-force balance

An original device was developed by our research group and used for quantitatively and qualitatively studying the stability mechanism of two liquid droplets in another liquid phase. The squeeze time can be employed to detect the stability of liquid droplets. The effect of water soluble emulsifier TX-100 and oil soluble one Span-80 on the squeeze times of both aqueous and kerosene droplets have been investigated. Moreover, the influences of three polyether demulsifiers with different structures, linear PEL, branched PEB and star-type PES, on the stability of liquid droplets have also been studied. Based on experimental results, the hydrophilic head group ethoxylation (EO) chain of TX-100 nearly flats at interface and forms compact interfacial film closed to water phase, which makes kerosene droplets stable at aqueous. On the other hand, two water droplets contain TX-100 will coalesce at once when they contact each other. For oil soluble emulsifier Span-80, the compactness of two sides of interfacial film leads to both stable water droplets and oil droplets. The molecular size of demulsifier may play the crucial role in controlling droplets coalescence: PEL with smaller size can easily destroy aqueous droplets in oil; PEB shows strong effects on both kerosene and aqueous droplets for it has a moderate molecular size; PES with larger size shows strong ability to destroy oil droplets in aqueous but little effects on aqueous droplets in oil.

Effect of different grinding fluids applied in minimum quantity cooling-lubrication mode on surface integrity in cBN grinding of Inconel 718

Inconel 718 (IN 718) is one of the important nickel based alloys that is being extensively used in aerospace industry. Being an aerospace material, surface integrity is of paramount importance due to high risk factor involved in this kind of industry. Superabrasive grinding wheels are believed to be superior over conventional wheels, which can improve the surface integrity of the ground component. Further, minimum quantity cooling lubrication (MQCL) is seems to be a promising technique that can also yield desirable surface quality. Therefore, in the present study IN 718 was ground with single layer superabrasive cBN wheel with neat oil, soluble oil water emulsion and different nanofluids in MQCL mode, and the surface integrity was studied. Flood cooling was also used as a benchmark. Residual stress, ground surface morphology, and surface roughness were studied using X-ray diffraction, scanning electron microscope, and 3D surface profilometer, respectively. Chip morphology was also studied using scanning electron microscope to correlate it with the surface quality of the job. Performance of MQCL neat oil was found to be the best as compared to other fluids in the context of surface integrity due to proper lubrication and grit penetration.

Grinding of WC-Co cermets using hexagonal boron nitride nano-aerosol

WC-Co cermets (ceramic-metal composites) were ground by a resin bonded diamond grinding wheel using hexagonal boron nitride (hBN) nano-aerosol to improve the grindability. This is a new generation grinding fluid and was produced by dispersing nano-sized hBN platelets in deionized water. Small quantity cooling-lubrication (SQCL) technology was employed to deliver hBN nanofluid in the form of nano-aerosol so that volumetric consumption rate could be kept at a very low value of 200 ml/h. The nanofluid, when separately characterized, demonstrated good lubrication and heat dissipation capability in reference with soluble oil, which is a commonly used cutting fluid for grinding. The superior tribological characteristics of hBN nanofluid were more pronounced at a high sliding speed of 1 m/s, as observed during a ball-on-disc test. However, the beneficial effect of using hBN nanofluid could be extracted more efficiently only in aggressive grinding condition. A clear drop in specific energy, favourable values of residual stress indicate the same. Prevalence of low grinding zone temperature was reflected through low specific energy values and finer but complex chip micromorphology. Overall the aqueous hBN nanofluid was proven to be a high performing grinding fluid suitable for SQCL application and WC-Co cermet grinding.

An investigation on application of nano-fluids in high speed grinding of sintered alumina

Ceramics are the most sought-after materials in various advanced engineering applications. Diamond abrasive machining is used to achieve dimensional tolerances for hard ceramic materials. Micro-brittle fracture and grain dislodgement are the primary material removal mechanisms which generate surface and sub-surface defects. High processing cost and manufacturing defects limit their widespread use. This paper investigates the effectiveness of different grinding environments in reducing the brittle fracture in high speed grinding of highly pure and dense alumina work samples using single layer electroplated diamond grinding wheel. Grinding environments included straight cutting oil, water soluble oil at 5% concentration (soluble oil), and two water based nanofluids of alumina and hBN, all in Minimum Quantity Lubrication (MQL) mode. Conventional flood cooling with 5% concentration of soluble oil in water was used as the benchmark. Grinding forces were measured to estimate the specific grinding energy and apparent coefficient of friction. Surface integrity aspects of ground samples such as surface morphology, surface roughness and residual stresses were studied using Scanning Electron Microscope (SEM), 3D surface profilometer and x-ray diffractometer, respectively. Morphology of the grinding wheel was studied using stereo zoom microscope. Based on the experimental observations, a new model is proposed to demonstrate the interaction of nanoparticles in the grinding zone for grinding of brittle materials including alumina. Results showed that the nanofluid MQL yielded highly fractured surface because of high contact stress fields, whereas straight cutting oil MQL provided better lubrication in the grinding zone which promoted ductile deformation. Compressive residual stresses of the order of 105 MPa were observed in the samples ground with straight cutting oil MQL which can improve the fatigue life. Single scratch experiments done using diamond indenter also showed better lubrication efficiency of the straight cutting oil in comparison with soluble oil.

Oil Recovery Tests by using Bio surfactant of Indigenous Pseudomonas peli and Burkholderia glumae Bacteria from South Sumatera at Various Temperature Conditions

The isolates of indigenous Pseudomonas peli and Burkholderia glumae bacteria were obtained from Babat Toman Village, Musi Banyuasin, South Sumatera which have a potential as bio surfactant. The bacteria are thermophile bacteria, and then they were used to produce bio surfactant by using molasses as carbon source. The bio surfactant were tested their ability to the oil recovery of soil contained oil 18.64%. The variables of treatments were temperatures from 40°C to 80°C. The results showed that the optimal oil recovery by using Pseudomonas peli and Burkholderia glumae were 2.20% and 18.19% at temperatures 80°C and 40°C respectively. The results of optimal oil recovery of each bacterium were analysed using gas chromatography to determine the constituent components of petroleum that can be extracted by using the bio surfactant. The bio surfactant of Burkholderia glumae dissolved hydrocarbons at a fraction of temperatures 133; 139; 155; 156.8; 165; 173; 190; 197.5 and 206.3°C with the total abundance of soluble oil 25.22%. Furthermore, the bio surfactant of Pseudomonas peli dissolved hydrocarbons at a fraction of temperatures 133.3; 134; 139; 140; 145 and 150°C with the total abundance of soluble oil 16.94%.

Assessing near-dry lubrication (35 ml/h) performance in hard turning process of hardened (48 HRC) AISI 1060 carbon steel

Turning hardened steel prevailingly initiates intense amount of heat generation and depletion of such extortionate heat from the cutting edge by the application of coolant and/or lubricant induces prolonged tool life and reduces the deterioration of surface quality. However, traditional heat extraction methods fail to satisfy legislation on environmental and health protection, thus hamper sustainability at colossal extent. This study explores and evaluates the propitious role and feasibility of near-dry lubrication (NDL) using soluble oil on the basis of chip tool interface temperature, surface roughness, and chip thickness ratio to compensate the growing demand for ameliorated product quality maintaining “Go Green, think Green and act Green” philosophy. Hard turning of AISI 1060 carbon steel (~ 48 HRC) was performed with the implementation of NDL technique which has been recognized as one of the practical ways to green manufacturing in the context of sustainable production. Herein, responses were also recorded for dry-cut and machining with conventional flood coolant to state a vivid comparison. Furthermore, analysis of variance is employed to analyze the effects possessed by machining parameters on the aforementioned responses and to devise prediction of responses with the aid of formulated mathematical equations. To conclude, NDL provides sufficiently low chip tool interface temperature, improves surface roughness of the machined part, and increases the ratio of chip thickness. Finally, due to significantly less consumption of cutting oils, chances of inhaling nerve-racking gases are foreshortened along with cost related to use and disposal of cutting fluids.

ANALISIS KEKERASAN BAJA S45C HASIL HARDENING DENGAN VARIASI MEDIA PENDINGIN

Steel has good mechanical properties compared with the other materials, that
 is strength, hardness, rigidity, etc. Specially the steel hardness can be increased by
 heat treatment (Hardening).
 The purpose of this research is to obtain information about hardness of S45C
 steel after hardening by variation of cooling media.
 This research were used Ø 25 mm x 10 mm S45C steel, Hardened by
 variation of cooling media and then they were tested by Rockwell Harness Test.
 The result showed that the hardness of S45C steel after hardening increased
 from about 15 HRC (before hardening) to 71.89 HRC (Brane quenching), 68.22
 HRC (Water quenching), 64.67 HRC (Water + Soluble oil quenching) and 56.89
 HRC (Oil quenching), but for the range were opposite to 3.84 HRC (Brane
 quenching), 4.24 HRC ( Water quenching), 4.22 HRC (Water + Soluble oil
 quenching) and 5.65 HRC (Oil quenching)

Effect of Cooling Media on Steel Hardness ST 37 On Conventional Lathe Process

This study aims to determine the type of air cooling media, soluble oil, and air to the result on lathe ST 37 steel. The cooling medium is very important to maintain boring tool deformation and can add product quality. In the process lathe of friction between the workpiece and chisel cut that can produce overheating and influence on the result of the slice boring tool on the workpiece. The research that will be carried out is experimental research with variables that are controlled that is feeding, deep of a cut, and spindle rotation and examination of the hardness of the specimen on the object before done lathe. The sample in this study which is ST 37 steel with diameter 25 mm and length 60 mm as many as 9 specimens which will be done lathe with different type media kind inprocess working. To know influence the type of cooling medium against steel ST 37 is done brinnel hardeness test using test equipment hardness tester. Of the 9 specimens lathe will be determined 3 points to do hardeness tests. From the result of hardness test and analysis obtained from hardness test on steel ST 37 average data that is use of soluble refrigerant media that produce a very good cooling at the time of the lathe process. The results of research is obtained that the use of soluble refrigerant media is the best with an average hardness of 224.10 kg / mm². On the lathe process, the cooling media has oil content will be able to maintain the scores hardness and time-worn on boring tool. Thus to maintain the hardness values can be used soluble oil cooling media and to increase the hardness values of workpieces can be used air cooling media.

Metalworking Fluid Exposure and Consequences on Skin Health in a Metal Machining Factory: Review Article

Metalworking fluids (MWFs) are a variety of substances can be used during machining of metals such as cutting, turning, grinding, milling and drilling. National Institute of Occupational Safety and Health (NIOSH) in United States of America has stated that MWFs available in different forms such as straight oil (neat oil), soluble oil (emulsifiable oil), semisynthetic MWFs, and synthetic MWFs and during the machining processes worker can be exposed to MWFs through skin contact and inhalation. MWFs in machining factory allow significant bacterial growth in the fluids and aerosols which cause dermatological and respiratory adverse health effects among exposed workers. skin diseases that MWF exposure can cause various morphology of skin disorders such as skin scaling or dryness. Semi-quantitative dermal exposure assessment methods (DREAM) in both occupational and epidemiological survey. The prevention of the health effects of MWF on skin systems would probably by enhancing the awareness of the workers towards the health effects of MWF and the appropriate safety methods need to apply regularly all along their working time.

Deactivation mechanism and activity-recovery approach of composite ionic liquids for isobutane alkylation

The deactivation mechanism and the activity recovery approach of composite ionic liquid (CIL), a kind of acidic chloroaluminate ionic liquids (ILs) modified with CuCl for the in 2013 successfully commercialized catalysis of isobutane alkylation are being discussed in this paper. CIL showed catalytic activity only in the presence of both Brønsted and Lewis acids. CIL deactivation was caused by the loss of Brønsted acidity and/or Lewis acidity. Brønsted acidity decreased by the loss of trace amount of formed chlorohydrocarbons with the outflowing alkylate. Lewis acidity was deactivated mainly due to the complexation of the formed acid soluble oil (ASO) with the CIL anions. Brønsted acidity was maintained by the continuous addition of hydrogen chloride (HCl) or tert-butyl chloride, and Lewis activity was recovered by AlCl3 addition. However, Brønsted acidity could not be recovered when Lewis acidity was lost and was thus dependent on Lewis acidity. Furthermore, ASO interacted with active components of CIL, causing the loss of copper via precipitation of CuCl which is the major contributor to the high selectivity. Therefore, CuCl was added simultaneously with AlCl3 to maintain the high selectivity of alkylate.

Performance evaluation of Titanium nitride coated tool in turning of mild steel

The growth in demand for bio-gradable materials is opened as a venue for using vegetable oils, coconut oils etc., as alternate to the conventional coolants for machining operations. At present in manufacturing industries the demand for surface quality is increasing rapidly along with dimensional accuracy and geometric tolerances. The present study is influence of cutting parameters on the surface roughness during the turning of mild steel with TiN coated carbide tool using groundnut oil and soluble oil as coolants. The results showed vegetable gave closer surface finish compares with soluble oil. Cutting parameters has been optimized with Taguchi technique. In this paper, the main objective is to optimize the cutting parameters and reduce surface roughness analogous to increase the tool life by apply the coating on the carbide inserts. The cost of the coating is more, but economically efficient than changing the tools frequently. The plots were generated and analysed to find the relationship between them which are confirmed by performing a comparison study between the predicted results and theoretical results.

Nutrient availability of different batches of wheat distiller’s dried grains with solubles for turkeys

ABSTRACTEffects of five different batches of wheat distiller’s dried grains with solubles (DDGS) were used to investigate bioavailability of energy and nutrients for turkeys. The laboratory analysis of the DDGS showed the largest variations for soluble non-starch polysaccharides, oil and ash. In total, 96 birds were fed one of six mash diets. The basal diet contained per kilogram 535 g wheat and 300 g soya bean meal, corresponding to 247 g crude protein and 12.6 MJ N-corrected apparent metabolisable energy (AMEn). Another five diets contained per kilogram 200 g of each DDGS samples in replacement for basal diet. Each diet was fed to eight pens with two female Premium turkeys following randomisation. The AMEn and the nutrient retention coefficients of the pure DDGS samples were obtained using the substitution method. The AMEn of the DDGS from batch A was higher (p = 0.048) compared to those from batches B and C, but did not differ from DDGS samples D and E. There were no differences in dry matter retention, nitrogen retention and fat digestibility between the DDGS samples tested. The AMEn of the DDGS samples correlated positively (p < 0.05) to the starch (r = 0.895) and the non-soluble non-starch polysaccharides contents (r = 0.940), and the red index of lighting (a) (r = 0.916), respectively. In general, findings from this study indicate bioavailability of energy and most nutrients to be in the range of published data with turkeys, and to vary between batches.

Bladder cancer and occupational exposure to metalworking fluid mist: a counter-matched case–control study in French steel-producing factories

ObjectivesTo assess the relationship between occupational exposure to metalworking fluids (MWFs) in the steel-producing industry and bladder cancer incidence.MethodsA nested case–control study on bladder cancer was set up in a...

Experiment and analytical model of laser milling process in soluble oil

The liquid-assisted laser machining process is a promising method to cut materials with minimum thermal damage caused by laser, and water is typically used in the process due to its high thermal conductivity, nontoxicity, and relatively low price. However, water can intrinsically oxidize ferrous metals and in turn deteriorate the workpiece through corrosion during laser ablation in water. This study has for the first time proposed laser ablation in soluble oil to effectively cut the ferrous metals by using laser in a high cooling rate and low potentiality of corrosion to the metals. A nanosecond pulse laser was used to scan over the AISI H13 steel sheet to create a square cavity, while the workpiece surface was covered by a thin and flowing soluble oil film throughout the laser milling process. The effects of laser scan overlap, traverse speed, and liquid flow rate on cavity dimensions and milled surface morphology were experimentally examined. The results revealed that a clean and uniform cavity with a smooth machined surface can be attained by using 70% scan overlap, 6 mm/s traverse speed, and 3.9 cm3/s soluble oil flow rate. Furthermore, analytical models based on heat transfer equations were formulated to predict the cavity profile and cooling of molten droplets in flowing liquid. The predicted profile was found to correspond well to the experiment, and the calculated temperature of cut particles can endorse the experimental findings on debris deposition and recast formation. The implications of this study could bring a new technological approach for damage-free fabrication and fine-scale manufacturing.

Some investigations in grindability improvement of Inconel 718 under ecological grinding

This work explores the improvement in grinding characteristics of Inconel 718 (IN718) using soluble oil under minimum quantity lubrication and liquid nitrogen (LN2) environments. The coolant flow rate in minimum quantity lubrication and LN2 grinding has been regulated through indigenously developed setups. Grinding performance has been studied in terms of on-machine measured grinding forces and centre line average surface roughness ( Ra). The obtained grinding characteristics have been compared with the outcomes under dry and wet grinding. Surface integrity of ground surface, wheel morphology, and chip formation characteristics has been studied using scanning electron microscope, energy dispersive X-ray spectroscopy, and atomic force microscopy. Analysis of variance has been carried out to capture the variability in the experimental data for tangential forces and Ra. The main effect of the factors and their first-order interactions have been considered, and second-order regression equations have been developed using response surface methodology. LN2 grinding has been proved to be more efficient as it yielded lowest grinding forces, least oxidation, minimal ground surface damage and better surface integrity. The occurrence of almost circular chips in dry grinding indicates severe oxidation, whereas small C-type chips formed under minimum quantity lubrication and LN2 conditions indicate effective cooling under these environments. The energy dispersive X-ray spectroscopy analysis of the ground surfaces also supports these results through the occurrence of the highest oxidation in dry grinding. From this work, it has been concluded that LN2 and minimum quantity lubrication grinding offer a clean and effective means to improve grinding performance of IN718 compared to dry and wet grinding.

Antibacterial Efficacy of Acetone Soluble Oil of Azadirachta indica on Some Bacterial Strains

Medicinal and pesticidal properties of neem (Aadirachta indica) have been described for more than 4,000 years. In the present study, antibacterial properties of Aadirachta indica seed oil have been investigated against Escherichia coli, Bacillus subtilus, Rizobium meliloti and Pseudomonas aeruginosa by disc diffusion method. At 100% concentration, acetone soluble oil possessed the highest antibacterial activity causing 18 mm zone of inhibition against E. coli and 17 mm against P. aeruginosa as compared to ciprofloxacin used as a positive control. The 1inhibition zone showed a significant difference across all the bacteria (p<0.01) and concentrations (p<0.001). This study focuses the use of neem oil as an alternative to ciprofloxacin.

Influence of cutting speed and cooling method on the machinability of commercially pure titanium (CP-Ti) grade II

The present investigation aims in highlighting the influence of cutting speed and an eco-friendly cooling technique during finish turning of CP-Ti grade 2. Experiments were performed at three distinct machining modes viz. dry cutting (DC), flood cooling (FC) and minimum quantity lubrication (MQL) using carbide inserts. Water soluble oil and vegetable oil were used as cutting fluids with FC and MQL respectively. The work material was turned at three different cutting speeds i.e. 51, 67 and 87 m/min whereas feed rate and depth of cut were kept as constant at 0.12 mm/rev and 0.5 mm respectively. A comprehensive exploration on the cooling effects of vegetable oil based MQL method on some of the key machinability aspects such as cutting force, tool wear, friction coefficient, chip morphology, chip reduction coefficient, micro hardness of machined surface, surface roughness and machining temperature is reported. The aforesaid turning responses were recorded and compared in order to exhibit the feasibility of MQL approach in comparison with dry and flood cooling approach. The results obtained during the investigation clearly established the superiority of implementing MQL for achieving improved machinability within a specified range of process parameters.

Full‐Scale Drinking Water System Decontamination at the Water Security Test Bed

The EPA's Water Security Test Bed (WSTB) facility is a full-scale representation of a drinking water distribution system. In collaboration with the Idaho National Laboratory (INL), EPA designed the WSTB facility to support full-scale evaluations of water infrastructure decontamination, real-time sensors, mobile water treatment systems, and decontamination of premise plumbing and appliances. The EPA research focused on decontamination of 1) Bacillus globigii (BG) spores, a non-pathogenic surrogate for Bacillus anthracis and 2) Bakken crude oil. Flushing and chlorination effectively removed most BG spores from the bulk water but BG spores still remained on the pipe wall coupons. Soluble oil components of Bakken crude oil were removed by flushing although oil components persisted in the dishwasher and refrigerator water dispenser. Using this full-scale distribution system allows EPA to 1) test contaminants without any human health or ecological risk and 2) inform water systems on effective methodologies responding to possible contamination incidents.