Detailed Project Report on Cutting Oil

CUTTING OIL

[EIRI/EDPR/4357] J.C.: 2543XL 

INTRODUCTION

Cutting  Oils are important among metal  working  lubricants not  only because of their requirement in large volume  but  also due  to important technical considerations in their  development, production  and  usage.  The sophistication and automation of machine tools is considerably influenced by the availability of right type of cutting oils. 

Metal   working lubricants are important and in   fact, necessary production aids to engineering industry and petroleum lubricating   oils   have   established   themselves   as   major constituents of such lubricants. Easy availability in wide range of viscosities and quality, as well as relatively   consistent price, unaffected by vagaries of nature, has been their mainstay. The petroleum lubricating oils, lack in so many properties but lend themselves easily for supplementing with chemicals and additives to suit diversely different applications encountered in working of metals. 

Cutting lubricants or cooling liquids as they are sometimes called are compounded oils or emulsions which are used wherever the cutting of metal is carried on. Cutting oils  are  important among   metal  working  lubricants  not  only  owing   to   their requirement  in large volume but also due to important  technical considerations  in their development, production and  usage.  The sophistication and automation of machine tools is considerably influenced by the availability of right type of cutting oils. 

The  major  function of cutting oil is to cool  the  cutting tool  as well as lubricating the face of the tool and  the  chip, and  preventing  the  chip  from  welding  to  cutting  edge.  In addition, cutting oils also provide a flushing action  for  chip removal,  leave  no  stain or discoloration on  the  work,  leave minimum  sediment  deposit  on the machine,  prevent  or  inhibit rusting  of  the machine and the work, resist  bacterial  growth, etc.

Metal working lubricants are broadly classified in the following categories:

Metal Forming and Deforming Lubricants

These types are used in operations like bar, wire, tube drawing, pressing, forging, rolling etc.

Cutting Oils

These are used in operations like turning, milling, gear cutting, drilling, grinding, broaching etc. 

Heat Treatment Oils

These types are used for metal quenching and tempering. 

The  efficient use of cutting oil in cutting operations  can result  in  better finish and precision of worked  piece,  longer tool  life,  higher cutting speeds lower power  consumption,  and easy starting of cutting operation. The main function of cutting oils is dissipation of heat and lubrication. Besides, they have important side functions. They help in removal of chip and swarf. By the combination of these functions and chemical activity, when necessary, they prevent welding of chip and tool. 

There are many facts to effective & efficient metal cutting. Any change which will improve one of these areas, improves the total operation.  

Cutting Oils    

A  wide variety of  cutting oil are available in the  market varying  in composition and form, starting from simple  solutions of  soap  in  water to  complicated  well  balanced  formulations containing   mineral   oils,  fatty   oils,   synthetic   fluids, emulsifiers, coupling agents, extreme pressure agents,  oxidation and rust inhibitors and bactericides. However cutting oils can be broadly classified into two main groups based on whether they contain water or not. The classification is as follows:-

 Neat cutting oil 

 Water based cutting oil 

Neat Cutting Oil

Neat cutting oil contains mineral oils alone or in combination with fatty oils and antiweld and antiwear additives. 

Water Based Cutting Oil

Water  is  a  very good base  for  cutting  oil   since cooling is one of the most important requirements of cutting  oil and  water  has  nearly  twice  the  specific  heat  of   mineral lubricating oils. In addition water is an inexpensive and readily available fluid. However, water lacks badly in lubrication, rusts and corrodes steel and other metals, and it has poor wettability. Therefore, now water is used in the form of oils, commonly known as soluble oils emulsifiers as well as solutions and dispersions of various chemical salts or soaps and synthetic fluids, along with proper additive which overcome the inherent limitation of water. 

Water based cutting oils are used where cooling is more important than lubrication such as at high speed cutting.  Both the emulsified oil and the synthetics are made up as concentrates which are mixed with water to the desired dilution in the user's plant. This saves transportation costs and storage space and causes no problem to the uses since the mixing requires only simple equipments. The emulsions are after cut as much as 50 to 1 with water and synthetics upto 150 to 1.  These  dilute emulsions  are circulated over the site of the cutting  operation and  besides  causing  effective cooling, carry  away  the  metal particles formed.

COST ESTIMATION

Plant Capacity            1 MT/Day

Land & Building (1800 sq.mt.)    Rs. 1.44 Cr

Plant & Machinery                    Rs. 82.25 Lac

Working Capital for 1 Month    Rs. 33.13 Lac

Total Capital Investment          Rs. 2.73 Cr

Rate of Return                          31%

Break Even Point                      60%

CONTENTS

INTRODUCTION

METAL FORMING AND DEFORMING LUBRICANTS

CUTTING OILS

HEAT TREATMENT OILS

CUTTING OILS

NEAT CUTTING OIL

WATER BASED CUTTING OIL

USES/APPLICATIONS

MARKET OVERVIEW

PROPERTIES & FEATURES

BIO-DEGRADATION OF CUTTING OIL

FEATURES

BIS SPECIFICATION

REQUIREMENTS FOR SOLUBLE CUTTING OIL

FORMULATION

RAW MATERIALS

SODIUM PETROLEUM SULPHONATE

STEARIC ACID

GLYCEROL MONOSTEARATE

POTASSIUM HYDROXIDE

TURPENTINE OIL

RAW MATERIAL SUPPLIERS

MANUFACTURING PROCESS STEPS

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

WTP FACILITY

SEWAGE AND WASTE WATER EFFLUENT

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT & MACHINERY

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

MIXING VESSEL/TANKS

D.G. SETS

POWER TRANSFORMERS

WTP PLANTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

PLATEFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE/SAFETY SYSTEMS

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

INSTRUMENTATION EQUIPMENTS

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE

POTENTIAL RISKS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)