This document describes the preparation and performance analysis of a metal working fluid made from castor oil using the Taguchi method. The objectives are to increase machining performance while producing a more environmentally friendly fluid. Castor oil and additives are emulsified to produce the fluid. An L9 orthogonal array experimental design is used to test varying machining parameters like speed, feed rate, and depth of cut. Analysis of surface roughness and tool/workpiece weight changes indicates the optimized parameters provide good surface quality and metal removal rate. The Taguchi method and vegetable oil-based fluid help improve machining operation and quality at low cost in an eco-friendly way.

1. PREPERATION OF METAL WORKING FLUID FROM
CASTOR OIL & PERFORMANCE ANALYSIS BY TAGUCHI
METHOD
Guided by: MR.S.Sankara kumar
Submitted by:
P.Mani kandan
G.Bala singh
S.Krishnan
M.Alagappapandian
Upload by: ALAGAPPAPANDIAN M

2. INTRODUCTION
Vegetable oils are viable and renewable source of environmentally benign oils.
The increased need for renewable and biodegradable lubricants can be traced to
stronger environmental concerns and growing regulations over contaminations and
pollution.
Here we are using castor oil based cutting fluids and tested by taguchi method.
The Taguchi method was developed by Dr. Genichi Taguchi of Japan who maintained
that variation.
Taguchi method is used to Identify the best parameters for machining operation.
Taguchi method is used to produce high quality product at low cost.

3. OBJECTIVES
Our ultimate aim of our project is to increase the performance of
machining operation and at the same time to produce more eco-friendly
metal working fluid.
Preparation of vegetable oil based metal working fluid by using emulsion
method.
The prepared metal working fluid is tested by taguchi method.
In taguchi method by varying different parameter to find out the best
quality product.

4. METAL WORKING FLUIDS
Cutting fluids are used to reduce the negative effects of the heat and friction on
both tool and work piece.
 The cutting fluids produce three positive effects in the process:
i. Heat removal elimination,
ii. Lubrication on the chip–tool interface
iii. Chip removal
 cutting fluids are classified into four categories:
i. cutting oils,
ii. soluble oils (emulsified oils, emulsions),
iii. synthetic (chemical) fluids,
iv. semi-synthetic (semi- chemical) fluids.

5. PREPARATION OF CUTTING FLUID
Base oil + Emulsifier + Other additives
Base oil- vegetable oil (castor oil )
Other additives
Emulsifier agent – sodium hydroxide
Neutralization agents
Corrosion and rust inhibitors
Lubricating additives (antiwear and EP additives)
Biocidies and fungicides
Foam inhibitors

6. PROCEDURE
COMPOSITION:-
Base oil – 40%
Water - 35%
Additives - 15%
Emulsifier - 5-15%
Initially castor oil is added to water for two minutes.
Then add all substances (emulsifier, additives) , they are mixed
together for 15 minutes followed by stirring process.
Now the emulsion will occurs.
After emulsion occurs it will undergoes to stability test.This will done
by keeping prepared solution for 24hours then it wants to be stable.
The percentage of emulsifier agent is depend on stability of
cutting fluid.
Fig.1 sample preparation of castor oil
based metal working fluid

7. EMULSION
A. Two immiscible liquids, not yet emulsified
B. An emulsion of Phase II dispersed in Phase I
C. The unstable emulsion progressively separates
D. The surfactant (purple outline around particles) positions
itself on the interfaces between Phase II and Phase I, stabilizing
the emulsion
An emulsion is a mixture of two or more liquids that are normally immiscible (no mixable or unbendable). Emulsions
are part of a more general class of two-phase systems of matter called colloids.

8. What is Taguchi method?
The goal of the Taguchi method is to produce high quality product at low cost to the
manufacturer and to society from variability in manufacturing processes.
Taguchi developed a method for designing experiments to investigate how different
parameters affect the mean and variance of a process performance characteristic that
defines how well the process is functioning.
The experimental design proposed by Taguchi involves using orthogonal arrays to
organize the parameters affecting the process and the levels at which they should be
varies.
Instead of having to test all possible combinations like the factorial design, the Taguchi
method tests pairs of combinations.
Here we are using L9 orthogonal method to find out good machining performance
parameters (cutting speed, feed rate, depth of cut, Lubricant ).

9. L9 Orthogonal Array
Here,
P1,P2,P3,P4 parameters

10. EFFECT OF MACHINING PARAMETERS IN PERFORMANCE

11. MODEL TABLBULATION
Experiment Cutting
Speed(rpm)
Feed
(mm/rev)
Depth of cut
(mm)
lubricant Surface
roughness
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1

12. TESTING
• Here we are considering carbide bit as cutting tool and stainless steel
(304ss) as work piece.
• From considering above table the machining process is done for constant
time. The initial and final weight of tool and work piece is calculated before
and after machining respectively.
• The tool weight is measure to calculate tool wear. And work piece weight is
measure to calculate metal removal rate (MRR).

13. CONCULSION
Thus the optimization method by taguchi for turning
process by considering various parameters has good
quality of good surface roughness.
Also the more eco-friendly vegetable oil based metal
working fluid is prepared.