ABSTRACT

The process of converting hot material into cold is called cooling

process. The main aim of the lathe coolant is converting hot input to the cold
material. The water pump is used to supply the coolant water into the work
piece. The lathe coolant consists of flexible tube and fuel pump.

The machining process of the hardening material is produces the large

amount of hot. The coolant pump is used to hot material into cold material.
 TABLE OF CONTENTS

CHAPTER TITLE

NO

ABSTRACT

1 INTRODUCTION

2 PLAN OF WORK

3 METHODOLOGY

4 COMPONENTS REQUIRED

5 WORKING PRINCIPLE

6 RESULT ANALYSIS

7 DESIGN OF LATHE COOLENT PUMP WITH

FITTING ARRANGEMENTS FOR LIGHT

DUTY LATHE

8 COST ESTIMATION

9 CONCLUSION

REFERENCES
 CHAPTER 1

INTRODUCTION

Mechanical Engineering without production and manufacturing is

meaningless and inseparable. Production and manufacturing process deals
with conversion of raw materials inputs to finished products as per required
dimensions, specification and efficiently using recent technology. The new
developments and requirements inspired us to think of new improvements in
air conditioning Engineering field.

The fabrication of cooling tower is our project; it is very useful in

medium scale industries by converting hot water into the cold water. The
cooling tower consists of more amounts of coolant tube and fan.

Recently, the concept of hard turning has gained considerable attention in

metal cutting as it can apparently replace the traditional process cycle of
turning, heat treating, and finish grinding for assembly of hardened wear-
resistant steel parts. Hard turning can possibly facilitate low process cost, low
process time, better surface quality, and lower waste.(1) Cutting fluids are
employed in machining to reduce friction, cool the work piece and wash away
the chips. With the application of cutting fluid, the tool wear reduces and
machined surface quality improves. Often the cutting fluids also protect the
machined surface from corrosion. They also minimize the cutting forces thus
saving the energy. There are mainly two types of cutting fluids used in
machining (I) neat oils or straight cutting oils (II) water-mix fluids.(2)Neat
oils are based on mineral oils and used for the metal cutting without further
dilution. They are generally blends of mineral oils and other additives. The
most commonly used additives are fatty materials, chlorinated paraffin,
sulfurized oils, and free sulfur. Sometimes organic phosphorous compounds
are also used as additives. Extreme pressure additives containing Chlorine,
sulfur, or phosphorous react in the tool–chip interface producing metallic
chlorides, phosphates, and sulfides, thus protecting the cutting edge (3). Neat
oils provide very good lubrication but poor cooling. Water-mix fluids are of
three types (a) emulsified oils (b) pure synthetic fluids (c) semisynthetic
fluids. Emulsified oils form an emulsion when mixed with water. They are
used in a diluted form with concentration of 3–10%. (4) Increasing of
productivity is impossible without utilization of modern tools and machines,
modern types of cooling and lubrication fluids When a cutting fluid provides
lubrication to a machining process, it serves to reduce friction levels and thus
moderate increases in temperature (5). For many machining operations,
however, the principal role of the cutting fluid is to remove heat during the
process, especially from the zones indicated in Figure.
Previous research has examined the perceived benefits of cutting fluids across
a wide variety of cases. It has also cast some doubts on the necessity of
cutting fluid use in some machining processes and under certain conditions.
Fluid-related costs are large because high production manufacturing plants
frequently utilize several cutting fluid reservoirs each containing thousands of
gallons of cutting fluid, and often an entire reservoir is flushed to clean the
system when quality issues arise (6) –certainly, reducing the amount of fluid
employed can produce significant cost and waste savings. Extensive use of
cutting fluids in machining operations leads to a sizeable waste stream.
Responsible handling of used/waste fluid is needed to avoid the
contamination of lakes, rivers, and groundwater. In addition to the
environmental challenges of managing a used cutting fluid waste stream,
cutting fluids also introduce several health/safety concerns. The National
Institute for Occupational Safety and Health (NIOSH) estimates that 1.2
million workers involved in machining, forming, and other metalworking
operations are exposed to metalworking fluids annually (7). Dermal exposure
to these fluids represents a health concern, as does the inhalation of airborne
fluid particulate.(8)The application of cutting fluids within a machining
operation often produces an airborne mist, and medical evidence has linked
worker exposure to cutting fluid mist with respiratory ailments and several
types of cancer (9). This makes the use of cutting fluids a health issue with
the potential of both long and short-term consequences.

The lathe is a machine tool which held and rotates the work piece
(metal, wood and other materials) on its axis to perform various operations
such as cutting, knurling, drilling and deformation with a tool bit that are
applied to work piece to create an object which has symmetry about an axis of
rotation.
The basic lathe that was designed to cut cylindrical metal stock has been
developed further to produce screw threads, tapered work, drilled holes,
knurled surfaces and crack shafts. Lathes are used in woodturning,
metalworking, metal spinning, and glass working. Lathes can be used to
shape pottery, the most well-known design being the potter's wheel. Most
suitably equipped metalworking lathes can also be used to produce most
solids of revolution, plane surfaces and screw threads or helices. Ornamental
lathes can produce three dimensional solids of incredible complexity. The
material is held in place by either one or two centers, at least one of which
can be moved horizontally to accommodate varying material lengths.
Examples of objects that can be produced on a lathe include candlestick
holders, cue sticks, table legs, bowls, baseball bats, crankshafts and
camshafts.
Bed – mainly support the whole machine.
Carriage – an assembly that moves the tool post and cutting tool along the
way.
Carriage hand wheel – a wheel with a handle used to move the carriage.
Chuck – a clamping device for holding the work piece in the lathe.
Apron – the front part of the carriage assembly on which carriage hand wheel
is mounted.
Cross slide - platform that moves perpendicular to the lathe axis under
control of the cross slide hand wheel.
Cross slide hand wheel – a wheel with handle used to move the cross slide in
and out.
Halfnut lever – a lever to engage the carriage with lead screw to move the
carriage under power.
Lead screw – a precision screw that runs the length of the bed and used to
drive the carriage under power for turning and thread cutting operation.
Tailstock – a cast iron assembly that can be slide along the ways and be
locked in place. Used to hold long work piece in place or mount a drill chuck
for drilling operation.
Ways - a precision ground surfaces along top of the bed on which saddle
rides. The ways are precisely aligned with the centerline of the lathe.
 CHAPTER 2
PLAN OF WORK

Planning is an important part of every project. Nobody plans to fail,

but they fail to plan. So before staring our project work we made some
planning for the successful completion of the project.

Selection of project
By considering the benefits of the project with the present conditions, the
amount of money can be invested, availability of the material, duration of
project, design and fabrication area the project can be planned.

Design and Drawings

Having been decided about the project to be manufactured, it must be
designed. The work of the design should be done very carefully by
considering all the relevant factors. After designing the project its detailed
drawing are prepared so that no doubts are left for future, detailed
specifications of raw materials and finished products should be decided
carefully along with the specification of the machine required for their
manufacture.

Purchase Consideration
It is very difficult to fabricate each and every components of the project.
Fabrication must be based on the accuracy that can obtained from the
components. If the project have some electronic components, then it is better
to buy the components from the market, and assemble it to the requirement.

Fabrication
Fabrication of the components can be done with the help of designed
calculations and drawings through different manufacturing process like
cutting, welding, shaping etc.

Assembly of the parts

The fabricated and purchased components are assembled together to complete
the fabrication process.

Cost Estimation
Cost estimation can be calculated by considering the material cost, labor cost,
transportation charges etc.
1. Material cost
2. Labor cost
3. Transportation expenses

Report
At the end of the project work, a report is prepared for future references. The
project report consists of all the items done during the project work
 CHAPTER 3
METHODOLOGY
A dual chamber fluid reservoir has been used to store and supply the
cutting fluid through a piping. Before staring the operation some cubes of ice
has been put on the fluid chamber to increase the cooling capacity of the
lubricant. As the liquid is a water based coolant the melted water does not
damage any property of the cutting fluid. The force of the fluid flow is
generated by compressed air. A regulating valve is integrated in the long
lining of fluid flow thus the proportion of fluid and air mixture can be
controlled. An air compressor has been used to get the compressed air for this
purpose and also for creating mist at the mixing nozzle. The Nozzle consists
of two inputs and one output. Cutting fluid and compressed air got in by the
inputs and a spray of mist spray out by the output. The whole system has been
controlled by the Adriano micro-controller system. A solenoid valve, thermal
infrared sensors and logic control circuit has been connected to the reservoir
system. Thermal sensors detect the temperature of the cutting zone without
contact and switch on or off the solenoid valve to deliver the coolant. The
triggering temperature can be defined by the logic control program, so any
kind of material hard or ductile is executable by the same system. The below
figure illustrates the flow diagram of the total coolant flow organization.
 CHAPTER 4
COMPONENTS REQUIRED

TEMPERATURE SENSOR

The Sensor used for the temperature measurement is thermistor.

Temperature sensor detect a temperature conditioning and change it into
electrical signal that can be used by the microcomputer makes decisions
based on information it receives from sensors.
Name : Thermistor
Type : NTC Thermistor
Temperature range : -50°C to 150°C
Resistance tolerances : ±2%
Overall lengths : 18mm- 78mm

AMPLIFIER

Amplifier is any device that will convert one signal often with a small
Amount of energy into another signal often with a larger amount of energy. In
automatic coolant unit the electrical signal from the thermistor is amplified by
using amplifier.
COMPARATOR

The comparator is used to compare the amplified electrical signal from the
amplifier to the comparator with the reference signal.

RELAY

A relay is an electrically operated switch. Current flowing through the coil of

the relay creates a magnetic field which attracts a lever and changes the
switch contacts. The coil current can be on or off so relays have two switch
positions and they are double throw (changeover) switches. Relays allow one
circuit to switch a second circuit which can be completely separate from the
first.

RESERVOIR
Reservoir is the storage area for the coolant and the coolant is supplied to the
specific location from the reservoir with the help of pump. The cold water
tank in a vented cold water system stores the large volume of water to supply
the hot and cold water systems that are not directly fed by the rising main.
The water level within the tank is controlled by a float operated valve which
is set to allow water to enter when the water level drops below the required
level. If the float operated valve should fail, water will continue to enter the
tank, raising the water level until it reached the overflow pipe, at which point
the water will be discharged though the overflow pipe and, hopefully, give a
warning of the problem. On plastic water tanks, the float valve needs to be
fitted with a backing plate to stiffen the side of the tank and prevent it flexing
when the valve is operated.

PIPE
 This is an open channel flow, the force required to make water move
along the channel against friction is supplied by the component of gravity
parallel to the bottom slope of the channel, rather than a pressure gradient as
is the case in pipe flow. Otherwise the two flows, uniform pipe and channel
flow, are very similar; in pipe flow a pressure gradient, uniform across the
pipe section, drives the flow through the pipe against friction, whereas a
component of gravity, again uniform across the channel cross-section, causes
the water to flow downhill. The freedom provided by the free surface,
however, allows open channel flows to take on a greater variety of flow
configurations and it is convenient, right from the outset, to define particular
regimes of flow:
Steady/Unsteady: As in other situations we say an open channel flow is
steady when the velocity at every point is constant with time; in turbulent
flow, the focus is on the steadiness of the mean velocity and the stationary of
the statistical properties of the turbulent flow field.
Turbulent/Laminar: The magnitude of the Reynolds number determines
whether the flow in the channel is laminar or turbulent; again there is a
critical Reynolds number above which the flow becomes turbulent.
Uniform/Non-Uniform: Uniform flow is when the streamlines are all
parallel to the channel bottom. Uniform flow is the exact counterpart to pipe
flow and in uniform flows the water velocity in the channel adjusts until the
force, due to bottom friction, retarding the flow, just balances the gravity
force acting downstream. In a uniform flow, pressure is hydrostatic
everywhere and adds little to the flow dynamics. When the streamlines in the
channel are not parallel to the bottom we call the flow varied or non-uniform.
 Gradually/Rapidly Varied: Non-uniform flows are further divided into
gradually varied and rapidly varied flows. Gradually varied flows are varied
flows that are dynamically locally uniform and are adequately described by
neglecting the vertical acceleration of the water and assuming that the
pressure varies hydrostatically over the depth. The flow depth may, however,
vary along the channel, adding a hydrostatic pressure force to the gravity
force, from where the flow depth is greater to where it is less. In gradually
varied flows the equations of motion remain essentially the same as those in
uniform flow except that a net pressure force, proportional to the gradient of
the water surface, is added to the gravity force. By comparison, rapidly varied
flows, are flows where the pressure departs from the hydrostatic variation and
some of the pressure force is used to vertically accelerate the water; in a
rapidly varied flow the water free surface responds to the rapidly varying
pressure gradient and undergoes a rapid change of height.
Sub/Supercritical: Waves on the surface of a river or channel are
common occurrences familiar to all of us. As we shall see in §8, surface
waves move over the water surface at a particular speed relative to the speed
of the water itself. We call a flow subcritical if the waves can move both
upstream and downstream, wave speed is great than the flow velocity and
supercritical if the water velocity is larger than the wave speed and all waves
generated in the channel are swept down downstream.
The above classification scheme is matrix like, but not all combinations
are physically possible. For instance, it is not possible for a flow to be both
uniform and unsteady. The great majority of open channel flows are turbulent
and either steady and uniform, steady and gradually varied, unsteady and
gradually varied, steady and rapidly varied or unsteady and rapidly varied.
Rapidly varied flows most often occur as flow adjustments between reaches
of gradually varied flows.

FLEXIBLE HOSES

Flexible hoses are used to transfer a wide range of fluids including

gaseous fluids, such as air, steam and gases, and liquids, such as water, oils
and chemicals. The hoses function for reciprocation of piping systems,
absorption of thermal expansion and vibration and centering of piping.
FLOW CONTROL VALVE
In any fluid power circuit, flow control valve is used to control the
speed of the actuator. The flow control can be achieved by varying the area of
flow through which the air in passing. When area is increased, more quantity
of air will be sent to actuator as a result its speed will increase. If the quantity
of air entering into the actuator is reduced, the speed of the actuator is
reduced.
PUMP
Hydraulic pumps are used in hydraulic drive systems and can be
hydrostatic or hydrodynamic. A hydraulic pump is a mechanical source of
power that converts mechanical power into hydraulic energy (hydrostatic
energy i.e. flow, pressure). It generates flow with enough power to overcome
pressure induced by the load at the pump outlet. When a hydraulic pump
operates, it creates a vacuum at the pump inlet, which forces liquid from the
reservoir into the inlet line to the pump and by mechanical action delivers this
liquid to the pump outlet and forces it into the hydraulic system. Hydrostatic
pumps are positive displacement pumps while hydrodynamic Pumps can be
fixed displacement pumps, in which the displacement (flow through the pump
per rotation of the pump) cannot be adjusted, or variable displacement pumps,
which have a more complicated construction that allows the displacement to
be adjusted. Hydrodynamic Pumps are more frequent in day – to – day life.
Hydrostatic pumps of various types all work on the Principle of Pascal's law
 CHAPTER 5
WORKING PRINCIPLE
The lathe cooling system is a system used to cool and lubricate the
work piece and chisel slurry in order to avoid any material metallographic
structural changes due to heat caused by friction of the work piece by chisel
lathes.
 The cooling pump on the lathe serves to circulate the coolant in order
to circulate continuously. By using the coolant supplied by the compressor to
the discharged object and cooling back into the reservoir through the filter,
the liquid will be inhaled by the pump through the suction channel.
Water blow
Water Blow is a coolant that is sprayed onto a work piece that has a slow heat
transfer rate. This is the most common refrigerant used because it is easy to
administer.
Straight Oils
Straight Oils are oils that cannot be emulsified and used in machining
processes in diluted form. This oil consists of basic mineral oil or petroleum,
and sometimes contains other lubricants such as fats, vegetable oils, and
esters. Straight Oils produces the best lubrication, but its cooling properties
are the worst among other cooling liquids
ADVANTAGES
 Simple in construction
 This system is noiseless in operation
 It is portable, so it can be transferred easily from one place to other
place
 Maintenance cost is low
 Low cost and high performance

DISADVANTAGES
 Additional cost is required

APPLICATION
 Industries Applications
 It is also used in a lathe and any machine
 CHAPTER 6
RESULT ANALYSIS
Tool wear:
It is the amount of metal shrank from the tool point to a degree which
eventually cause distorted operation on the work-piece. When cutting velocity
is high as 120 m/min, the chip makes fully plastic or bulk contact with the
tool rake surface and prevents any fluid from entering into the hot chip- tool
interface. This will results in high cutting force. When cutting velocity is less,
feed and depth of cut is more the cutting force will be more. Lubricant or
cutting fluid mitigates the effects of friction as to heat generation on the
cutting zone.

The average tool wear for the experimental conditions respective to different
cutting conditions. It is evident that in the Flood cooling condition (A) the
tool wear is maximum and intelligent coolant supply minimizes that tearing
down of tool. Hence improve tool life as to machining performance.
Temperature variation with the change in depth of cut:
Temperature is the key parameter of the cutting zone as all operations
performed in the machine engender heat and increase temperature. This heat
or temperature is involved in the development of high friction, residual stress,
deformation of both tool and work piece and high surface roughness.

The above figure it is apparent that intelligent cooling of cutting zone render
most consistent temperature control over flood or pulsed jet system. When the
IR sensor detect a temperature of 40oC or higher it opens the valve to deliver
fluid. This fluid is mixed up with ice at the reservoir so it is much cooler than
the cutting zone temperature. Thus the coolant takes away a lot of heat and
reduce the machining temperature. In case of flood cooling a large amount of
coolant wasted away but carry less heat because of the specific heat of water.
In the occasion of pulsed jet and intelligent cooling the lubricant is supplied
in the form of mist so it can carry a lot of heat with it. Furthermore the
intermittent cooling of pulsed jet provides same amount of mist after certain
interval which cannot handle capricious temperature changes due to high
depth of cut or other machining conditions.
Surface roughness
Surface roughness is directly related to the cutting edge of the tool and the
chip removal along with the machinability index of the cutting forces.

The figure shows substantiate the effectiveness of the intelligent cooling

system. The flood cooling and pulsed jet cooling reduce the surface roughness
though not as appositely as the intelligent system. In the advanced intelligent
coolant supply method maximum surface roughness found is 18 µm. whereas
the value is 23 µm & 19 µm for flood and pulsed jet cooling respectively.
Tool life
It is also dependent on the temperature of the cutting zone and the feed rate
and depth of cut. Tool life can be increased by reducing the cutting zone
temperature which has been done here by using cold cutting fluid in the form
of mist according to the system requirement.

The figure illustrates the flood coolant flow provides maximum tool life than
other two, however the wastage of fluid is high in the conventional flood
cooling. Compared to the pulsed jet cooling, intelligent coolant flow offers
more tool life.
Amount of coolant used
The key and desired parameter of the experiment is to find the coolant
needed for some analogous coolant supply method. Because in conventional
flood cooling large amount of liquid get away without taking any heat which
eventually cost higher machining cost.

The Figure depicts the amount needed for the three types of cooling
and it is apparent that the flood cooling takes a lot more amount than other
two method. Only 21 ml/min coolant flow is needed on average of 1 hour
time for delivering coolant to the machining zone. Though the amount is a bit
higher than pulsed jet coolant, the overall performance of the proposed
method facilitates us to demonstrate the better phenomena.
 CHAPTER 7

DESIGN OF LATHE COOLENT PUMP WITH FITTING

ARRANGEMENTS FOR LIGHT DUTY LATHE

 CHAPTER 8
COST ESTIMATION

Sl.NO PARTICLES AMOUNT

1 Material cost 4000

4 Manufacturing cost 500

5 Labor cost 500

6 Transport cost 600

7 Over head charges 400

TOTAL COST 6000

 CHAPTER 9
CONCLUSION
Industrial operation depends upon machinability on a large scale. An
extensive examination of the functions of cutting fluids and interactions with
other machining system components has led to a general understanding of the
roles that cutting fluids play in a metal cutting process. It is manifest on
comparing those conventional cooling models with the novel method that
proposed coolant supply practice would be more economical and convenient
for manufacturing industry. Based on experimental conclusions the process
original cost effective lubrication could be asserted as the optimum. Though
future research will be performed on low cost hybrid machining.
Environmental and health hazards due to the over usage of the cutting liquids
will be a key concern for the further study.
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