Ogbe et al, Development and Performance Evaluation of Green Machine Cutting Fluids

from Local Agro-Nuts Waste, TAJET 3(1), June 2023: 35-42

Development and Performance Evaluation of Green Machine Cutting

Fluids from Local Agro-Nuts Waste.
E. E. Ogbe1*, E. A. Ada1, A. L. Erekosima1
1
Department of Marine Engineering, Nigeria Maritime University, Okerenkoko, Delta State, Nigeria
*
[email protected]; [email protected]; [email protected]

ARTICLE INFO AB S T RA C T
H is to ry : A study on the evaluation of Ube (canarium schweinfurthii. L) and Sandbox seed (Hura crepitans.
Received: 18th April, 2023 L). as vegetable based cutting fluids (VBCFs) was carried out. A work piece of 25 mm mild steel
(AISI 1020) was used in surface turning operation with the Agro-nut waste fluids and commercial
Accepted: 18th May, 202 cutting fluids (Mobil cot 100 and Rando HD) using gravitation method. The turning was performed
Received in revised form: at varied spindle speeds of 80, 120, 160 and 180 rpm at constant 0.5 mm/rev feed rate and 2 mm
30th May, 2022 cutting depth. The design of an experiment through Taguchi techniques was carried out with three
Published: 30th June, 2023 input parameters (cutting speed, cutting depth and cutting time) and three output parameters
(temperature, surface roughness and chip thickness). The input parameters were varied using the
different machine cutting fluids so as to determine the performance of each of the cutting fluids
K ey w o rd s based on the three output parameters. It was observed that Sand box 1 showed better surface
cooling characteristics and had the least value of surface temperature at 80 rpm and as well as a
Agro-Nuts waste, Chip thickness, lower chip thickness compared to the commercial cutting fluids. It was also observed that in all the
Cutting fluid, Gravitation method, formulations, UBE 1 had the lowest chip thickness compared to the commercial cutting fluids and
Green, Performance evaluation. other formulations. Finally, in comparison with the two commercial cutting fluids formulations
Ube (canarium schweinfurthii. L) and Sandbox seed (Hura crepitans. L) oil showed good lubrication
properties derived from chip thickness measurement in both formulations thereby making it more
humanly and environmentally friendly.

© 2022 TAJET All rights reserved

1.0 Introduction
Mineral oils have been in use as the traditional source of cutting In addition, agro-nut oil based cutting fluids have reduced
fluids in machining a number of metals and alloys because of their overall volume of fluids used for lubrication due to their higher
suitable lubricating properties on both the work piece and the cutting viscosity compared to the mineral oils-based fluids. Mineral oils are
tools [1]. However, there are now myriad of challenges posed by petroleum based cutting fluids, which are easily obtainable in
using such oils as lubricants in most of today’s application. Growing markets and are relatively excellent lubricants, but their continuous
environmental concerns such as renewability, biodegradability, usage in machining will pose environmental contamination and
safety and health of operator’s demand serious attention [2]. The health problems to operators [3]. Thus, the use of agro-nut oil-based
price of mineral oil product seems lower compared with the market cutting fluids will be significant to systematically overcome these
prices of agro-nut oil-based products but biodegradability, limitations and thus be a suitable alternative to mineral oil-based
availability and numerous benefits of other by-products of the agro- cutting fluids. There are few challenges associated with the use of
nut oils have made them more suitable and economical to use. agro-nut oil-based as cutting fluids. These include their low
Furthermore, the recent economic reality in most countries due to temperature viscosities, problems of oxidative and hydrolytic
high prices of petroleum products is also a motivating factor for the instabilities associated with the triglycerides naturally present in
present work in that petroleum-based cutting fluids are themselves them [3]. These triglycerides are present in agro-nut oil-based as
limited resources. In Nigeria, for example, the government has free fatty acids (FFA) [4]. The effect of these FFA can be neutralized
removed oil subsidies, which automatically translated into increased by an effective antioxidant which may be used as additives. This
petroleum products prices thus informing the need for an alternative justifies the use of environmentally friendly antioxidants, vitamin C
source of cutting fluids. Agro-nut oil-based are plant-based rich lemon extract, used as an additive in the present study in order
products, which are reared and refined for specific performance to promote the culture of a green and safe ecology. The primary aim
properties and other requirements. Recent studies have shown that of applying cutting fluids during machining is to eliminate,
bio-based cutting fluids have better lubricities and their viscosities overcome or at least reduce the heat generation effect, friction and
reduce significantly well at high temperature than the mineral oil- corrosion of both the tool and the work piece [5]. Their resulting
based oils [3]. positive effects include prompt heat removal, lubrication on the

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chip-tool interface and chip removal by constantly cleaning the determine their performance as coolant and lubricant during
machined zone [6]. machining operation.
Heat is generated and built-up at the region between the tool’s
rake and/or flank faces and the work piece by the action of rubbing 2.0 Materials and Methods
together of the tool and work piece. This may lead to generation of The agro-nut oils were obtained from Ube (canarium
tensile residual stresses and micro cracks at the material surface [7]. schweinfurthii. L) and Sandbox seed (Hura crepitans. L). The two
Frictional energy develops between the duo which leads to rapid tool nuts were purchased from the market and washed so as to remove
wear and reduction in tool life. As cutting fluid is applied during all impurities. The shells of the two nuts were removed by breaking
machining operations, it removes heat by carrying it away from the it manually and then the internal part of the nuts were washed again
cutting tool/work piece interface. This cooling effect prevents tools to remove any impurities from the shells. The Inner solid obtained
and work piece from exceeding their critical temperature range from the nuts were dried at low temperature for 2 hours after which
beyond which the tool softens and wears rapidly. Fluids also they were mashed into smaller particles using a commercial milling
lubricate the cutting tool/work piece interface, minimizing the machine and was subjected to tension load so as to extract the oil
amount of heat generated by friction. A fluid’s cooling and from the meshed particles by mechanical screw press equipment.
lubrication properties are critical in decreasing tool wear and The oils were sieved to remove any foreign particles or dirt.
extending tool life [7]. Cooling and lubrication are also important in Two different formulations from Ube oil (canarium
achieving the desired size, finish and shape of the work piece. No schweinfurthii. L) and Sandbox seed oil (Hura crepitans. L), with
one particular fluid has cooling and lubrication properties suitable 80% and 40% as base oil respectively were blended as shown in
for every metalworking application. Straight oils provide the best Tables 1 and 2. The formulations obtained were used as the cutting
lubrication but poor cooling capacities. Water, on the other hand, is fluids in the cutting operation. The physiochemical properties of the
an effective cooling agent, removing heat 2.5 times more rapidly based oil like their viscosity, relative density, pH, refractive index,
than oil. Water is a very poor lubricant when used alone and causes pour point, acidic value, iodine value, saponification value, flash
rusting. Soluble oils or chemicals that improve lubrication prevent point, were tested before blending. Cutting speed, cutting time and
corrosion and provide other essential qualities must be added in cutting depth are the cutting parameters considered in the turning
order to transform water into a good metalworking fluid [7]. The operation, while the performance of the cutting fluids considered are
sustainability of the use of cutting fluids and other lubricants can be critical temperature, chip thickness and surface roughness. The
divided into two aspects [8]. The first aspect is about the origin of cutting operation involved turning of 25 mm diameter of a
the resources, which can either be fossil or renewable raw materials, cylindrical rod on a lathe machine at constant cutting depth of 2 mm
such as mineral oils and vegetable oils, respectively. The other at a federate of 0.5 rev/mm.
aspect examines the environmental pollution associated with use
and discharge of these products. The carbon cycles of mineral oil- 2.1 Physicochemical Analysis of the Agro-nut base oil
based products are not closed, but open. This leads to an increase in The Physicochemical properties of the both Agro-nut base oils
content of atmospheric carbon dioxide and thus contribute to global were analysed. The physical properties looked at were Viscosity,
warming, an issue of concern to the entire globe. Contrary to mineral Specific Density Refractive Index, Specific Gravity, Percentage
based oils, the carbon cycle of products of renewable resources Yield, pH Value, Pour Point and Flash Point. The Chemical
(agro-nut oil-based) is closed. The amount of carbon dioxide properties considered were Acidic Value (mgKOH/g), Iodine Value
liberated during disintegration of organic chemicals equals the (gl2/100g), Peroxide Value, Saponification Number (mgKOH/g).
amount of carbon dioxide that was originally taken up by the plants
from the atmosphere [8]. 2.2 Criteria considered to determine the performance of the Cutting
In this study, Taguchi experimental design was used, varying Fluids
The developed Cutting fluid performance were analysis base on
the cutting machine parameters such as the cutting speed, depth and
the temperature, surface roughness and the thickness of the chips,
time respectively for measuring the temperature, thickness of the
and the input parameters considered were the cutting speed, cutting
chips and surface finish and using two Agro-nuts called Sample A
time and cutting depth.
and Sample B respectively, and a purchased conventional cutting
fluids (control samples). Samples A and B were used differently so
2.3 Experimental Procedure for the Turning Operation
as to determine the performance of each of the developed cutting
The metal turning operation was carried out on a lathe machine
fluids and were compared with the purchased Conventional Cutting
with a cutting speeds of 80, 120, 160 and 180 rpm. The feed rates
Fluids (Control Samples), using the ability of each sample to

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𝑛
0.5 mm/rev and the cutting depth 2 mm were kept constant. The 𝑆⁄ = −10 log (1⁄𝑛 ∑ 𝑦 2 )
𝑁 10 𝑖 (1)
cutting fluids were applied directly between the work piece and 𝑖=0
work tool through gravitational method. A Vernier caliper was used where 𝑦𝑖 is the ith measured value in one cutting operation and n is
to determine the thickness of the chips produce during each cutting the measurements values in a trial and row.
operation. The surface finish tester was used to determine the
surface roughness and the interfacial temperatures at the cutting
zone were determined by infra-red thermometer.

2.4 Statistical Analysis of the data gotten from the experiments

The experimental results obtained from the experiments were
analyzed using Signal to Noise (S/N) ratio and regression analysis
using the formula in equation 1.

Table 1: Cutting fluid formation of sample 1

Material Ube 1 (Canarium Sandbox 1 (Hura Commercial Cutting
schweinfwrthii L) Crepitans L Fluid (Mobil cot 100)
(% composition) (% composition) (% composition)
Base oil 80 80 80
Washing Soap 10 10 10
Phenol 5 5 5
Sulphur 5 5 5

Table 2: Cutting fluid formation of sample 2

Material Ube 2 (Canarium Sandbox 2 seed Commercial Cutting
schweinfurthii. L) (Hura Crepitans. L) Fluid (Rando HD)
(% Composition) (% Composition) (% Composition)
Base oil 40 40 40
Oleic Acid 40 40 40
Tri-ethanol Amine 20 20 20
Sulphur 5 5 5

3.0 Results and Discussion 3.2 Physicochemical properties of the base-oil

3.1 Seed Oil Yield after cold pressing The Acidic value of the developed cutting fluid Ube (canarium
Figure 1 clearly shows the seed oil yield, after drying, crushing schweinfurthii. L) and Sandbox seed (Hura crepitans. L) are lower
and cold pressing. Ube (Canarium Schweinfurthii. L) showed the than the commercial cutting fluid as soon in Table 3.
better oil yielding potential compare to sand box seed (Hura Flash point of oil is the temperature at which the oil will ignite as
crepitans. L). Equations 2 and 3 were used to determine oil yield soon as it been exposed to source of heat. Any liquid with flash point
base on seed and cake weights respectively. greater than 60oC is highly inflammable. The flash point of Ube oil,
Sand box oil, Mobil cot 100 and Rando HD are 209.432, 222.063,
𝑌1 = 𝑤1 − 𝑤2𝑤1 × 100% (2) 195.342 and 213.953oC, respectively. Since the developed cutting
𝑌2 = 𝑤1 − 𝑤2𝑤2 × 100% (3) fluid is above 60 oC, which is greater than temperature of
flammability, this makes the cutting fluid suitable for cutting
operation and ease for surface cleaning.

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45 42
Yield based on seed Y1 Yield based on cake Y2 39
40
35
Oil yield (%wt)

30
30 28

25
20
15
10
5
0
UBE
Seed Samples SAND BOX
Fig. 1: Percentage oil yield of UBE and Sand Box seeds based on seed (Y1) and Cake (Y2) after cold pressing

Table 3. Physico-chemical Properties result of the extracted raw Oils samples without blending
Cutting Fluids UBE OIL SANDBOX OIL MOBIL COT RANDO HD
100
Saponification 171.214 165.729 171.382 165.451
Value (mg KOH/g)
PH Value 7.14 7.01 7.12 7.13
Peroxide Value 1.024 0.919 1.131 1.103
Specific Gravity @ 0.814 0.968 0.806 0.817
(25oC)
Iodine Value 117.975 123.812 117.854 123.244
(gl2/100g)
Refraction Index 1.845 1.372 1.187 1.671
Viscosity @ 40(oC) 4.012 4.332 4.233 3.730
(cSt)
Specific Density 0.684 0.729 0.698 0.727
(mg/ml)
Pour Point (oC) -0.208 -0.108 -0.303 -0.098
Flash Point (oC) 209.432 222.063 195.342 213.953
Acid Value 2.272 2.676 3.535 3.450
(mg KOH/g)

3.3 Cooling effect variation with VBCF base-Oil type, concentration work piece as the speed increases, irrespective of the developed or
and speed commercial cutting fluid because of the lower surface temperature
Figures 2 and 3 show the different responses of temperature of at lower speeds for all cutting fluids.
the developed cutting fluids and commercial cutting fluid with Cassin and Boothroyd (1965) reported that cutting fluid is
respect to the cutting speed. It is seen that, as there is increase in the carried away fast before if get to the cutting zone at high cutting
cutting speed, there is increase in the surface temperature between speed and the time required for the cutting fluid to react with the
the workpiece and cutting tool. There is less cooling effect on the

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metal surface is very short. It was concluded that at low speed, For the 80% developed cutting fluid shown in figure 2, at 80rpm
lubrication occurs through diffusion in the work piece. and 120rpm there are comparable similar cooling effect for all the
During cutting operation the heat generated on the shear plane cutting fluid. But for 160rpm and 180rpm Sandbox seed 1 (Hura
is carried away by the chips, it only little of the heat that is conducted crepitans. L), have the best cooling (quenching) properties, followed
into the work piece. At very high temperature the heat generated by Ube 1 (canarium schweinfurthii. L), then finally the commercial
from the workpiece exceeds the quantity of heat that can be carried cutting fluid (Mobil cot 100). This shows that cutting fluid
away by the cutting fluid and chips. Vapour film that is form around performance depend on the cutting process and the time required for
the workpiece helps for slow cooling of the work tools. chemical equilibrium to be establish on the surface of the metal.
Agboola et.al (2015), reported that in gravitational cooling, heat It was observed from figure 3 that among the 40% vegetable
is transfer due to vaporization. And he said the duration in which cutting fluid formation, it was seen that Sand Box seed 2 (Hura
maximum cooling occur is dependent on the properties of the cutting crepitans. L), have the best cooling characteristics followed by the
fluid. In this study, gravitational cooling method was used, and the commercial cutting fluid Rando HD, then lastly Ube 2 (canarium
rate of heat transfer is based on heat of vaporization. schweinfurthii. L).

250
UBE 1 SANDBOX 1 MOBIL COT 100
200 69.6
Temperature °C

64.7
58.3
150 51.6
62.5 67.4
100 50.5 53.9

64.2 69.1
50 54.3 56.5

0
80RPM 120RPM 160RPM 180RPM
Speed
Fig. 2: Surface temperature response for cutting fluids with formulation-1

250 UBE 2 SAND BOX 2 RANDO HD

61.1 64.8
200 57.4
52.9
Temperature

150 64.7 65.2

60.8
50.8
100 68.4 66.9
54.7 61.7
50

0
80 120 160 180
Speed
Fig. 3: Surface temperature response for cutting fluids with formulation-2

3.4 Chip thickness variation with VBCFs base-Oil type, chips formed during machining process is determined by the quality
concentration and speed and type of machining process. Formation of chips does not only
Deformation of work piece results to chip formation due to the depend on the shear force applied or material of the work piece, but
shear force applied during cutting operations. The size and shape of

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also on the grain structure of the work piece and the cutting fluid In Figure 4, it is seen that for both the developed vegetable
used. cutting fluids and commercial cutting fluid at different cutting
Figures 4 and 5 shows clearly that as the cutting speed speeds, Ube 1 (canarium schweinfurthii. L) had the least chip
increases, the thickness of the chips increases at different cutting thickness followed by Sandbox seed 1 (Hura crepitans. L) and then
depth, for both the developed vegetable cutting fluid and the Mobile cot 100. While for figure 5 between cutting speed of 80 rpm
commercial cutting fluid, the speed increases due to tool interface and 120 rpm, Ube 2 (canarium schweinfurthii. L) had the least chip
and temperature increase on the work piece. There is an agreement thickness followed by Sandbox seed 2 (Hura crepitans. L) and then
with the work of Kulkarn et.al (2014). He said that chips produce Rando HD, but for 160 rpm, Sandbox seed 2 (Hura crepitans. L)
are continuous at high speed rate either under wet or dry condition had the least chip thickness followed by Rando HD then finally Ube
while at low-speed rate, the chips are continuous with helical shape. 2 (canarium schweinfurthii. L). At 180 rpm the commercial cutting
There was chip thickness decrease in wet condition, owning to fluid Rando HD had the least thickness, followed by Ube 2
the reduction of the temperature between the surface of the work (canarium schweinfurthii. L) and then Sandbox seed 2 (Hura
piece and work tool. This implies that the cutting conditions and crepitans. L). This can confirm that the properties and composition
cutting fluid are the significant factors that affect chip formation and of the cutting fluid will determine the chip thickness.
chip thickness. Figure 4 and 5 shows that the properties and
composition of cutting fluids determines the chip thickness from the
work piece.

0.6
UBE 1 SANDBOX 1 MOBIL COT 100
Chip Thickness (mm)

0.5

0.4

0.3

0.2

0.1

0
80 120 160 180
Speed (Rpm)
Fig. 4: Surface temperature response for cutting fluids with formulation-1

0.6
UBE 2 SAND BOX 2 RANDO HD
0.5
Chip Thickness (mm)

0.4

0.3

0.2

0.1

0
80 120
Speed (Rpm) 160 180

Fig. 5: Surface temperature response for cutting fluids with formulation-2

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3.5 Surface roughness (finish) variation with VBCF base-Oil, by Sandbox seed 1 (Hura crepitans. L), then last the commercial
concentration and speed cutting fluid (Mobile Cot 100). While for Figure 7, commercial
Paul et al [12], reported that vibration, minimum chip thickness cutting fluid (Rando HD) have the least surface roughness, followed
and damage on the cutting edge can affect surface roughness in any by Sandbox seed 2 (Hura crepitans. L), then finally Ube 2
turning operation. However cutting fluid also determine the surface (canarium schweinfurthii. L). it is evident that high speeds reduce
roughness of the workpiece. It was seen in figure 6 and 7 that as the vibration and forces and the developed vegetable cutting fluid
cutting speed increases, the surface roughness reduces in all both the enhance surface finish of work piece in turning operation. Ube
developed vegetable cutting fluid and the commercial cutting fluid. (canarium schweinfurthii. L) had the least surface roughness at 180
From Figure 6, throughout all the cutting speed, Ube 1 rpm.
(canarium schweinfurthii. L) had the least surface roughness, follow

3.5 UBE 1 SANDBOX 1 MOBIL COT 100

3
Roughness (μm)

2.5
2
1.5
1
0.5
0
80 120 160 180
Speed (Rpm)
Fig. 6: Chip thickness response for cutting fluids with formulation-1
3.5
UBE 2 SAND BOX 2 RANDO HD
3
Roughness (μm)

2.5

1.5

0.5

0
80 120 Speed (Rpm) 160 180
Fig. 7: Chip thickness response for cutting fluids with formulation-2

Conclusion characteristics and have the least value of surface temperature at

The effect of Ube (canarium schweinfurthii. L) and Sandbox 80rpm. And have a lower chip thickness compare to the commercial
seed (Hura crepitans. L), as a cutting fluid were evaluated in the cutting fluids. In all the formulations UBE 1 have the lowest chip
turning operation of AISI 1020 mild steel based on the surface thickness compared to the commercial cutting fluids and other
temperature, chip thickness and surface roughness, and the results formulations. Rando HD have the least surface roughness at 180
were compared to those of the commercial cutting fluids. The rpm compare to the vegetable base oil and other commercial cutting
following conclusions were drawn from the analyzed results. In the fluid. It was also seen that as the cutting speed increases the surface
both formulations, Sand box 1, shows the best surface cooling roughness reduces. Finally in comparison with the two commercial

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cutting fluids formulations Ube (canarium schweinfurthii. L) and [6] Aluyor, E.O., Aluyor, P. and Ozigagu, C.E., “Effect of
Sandbox seed (Hura crepitans. L) oils show good lubrication Refining on the Quality and Composition of Groundnut Oil”.
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[7] Petterson, A., “High Performance Base Fluids for
Acknowledgements Environmentally Adapted Lubricants”. Journals of Tribology
International 40: 2007, 638-645.
I really want to appreciate Tertiary Education Trust Fund
[8] Salete, M.A. and Joao Fernando Gomes de Oliveira.,
(TETFund) through Nigeria Maritime University Okerenkoko,
“Vegetable based cutting fluid- An environmental alternative
Delta State for funding this research. And also, my research team, to grinding process”. Proceedings at 15th CIRP International
Engr. Adah Augustine Elakpa and Engr. Anthony Longjohn Conference on Life Cycle Engineering, Brazil. 2008.
Erekosima for making this work a success. [9] Cassin, C. and Boothroyd, G.,“Lubrication Action of Cutting
Fluids”. Journal of Mechanical Engineering Science. 7: 1965,
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