Detailed Project Report on Cutting Oil

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CUTTING OIL

[EIRI/EDPR/1089] J.C.: 9733, 9750

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.

COST ESTIMATION

Plant Capacity 0.50 MT/Day

Land & Building (200 sq.mt.) Rs. 12.92 Lac

Plant & Machinery Rs. 7.20 Lac

Working Capital for 2 Months Rs. 29.53 Lac

Total Capital Investment Rs. 53.97 Lac

Rate of Return 29%

Break Even Point 57%

CONTENTS

INTRODUCTION

1. METAL FORMING AND DEFORMING LUBRICANTS

2. CUTTING OILS

3. HEAT TREATMENT OILS

CUTTING OILS

THE CLASSIFICATION IS AS FOLLOWS:-

NEAT CUTTING OIL:-

WATER BASED CUTTING OIL:-

CHEMICAL SOLUTIONS:-

TABLE: CLASSIFICATION OF METAL WORKING FLUIDS

TYPES OF CUTTING FLUIDS

USES AND APPLICATION

PROPERTIES AND CHARACTERISTIC

DESCRIPTION/APPLICATION

BIO-DEGRADATION OF CUTTING OIL

CUTTING OIL

FEATURES

DESCRIPTION

DIRECTIONS

PACKAGING

B.I.S SPECIFICATION

FOR CUTTING OIL

REQUIREMENTS FOR SOLUBLE CUTTING OIL

FOR NEAT CUTTING OIL

TABLE

MARKET SURVEY

PRESENT MANUFACTURERS/SUPPLIERS

FORMULATIONS OF CUTTING OIL

FORMULATION NO-1

FORMULATION NO-2

FORMULATION -NO- 3

FORMULATION- NO-4

SULFONATED BASE CUTTING OIL

FORMULATION NO-5

FORMULATION NO-6

OTHER FORMULATIONS OF CUTTING OIL

SULFONATED BASED SOLUBLE CUTTING OIL

FORMULATIONS OF OTHER SOLUBLE OIL

OIL-IN-WATER BASED CUTTING OIL EMULSIFIER

(OIL IN WATER EMULSION)

CUTTING AND COOLING OIL EMULSIFIER:-

SOLUBLE CUTTING OIL NO. 1:-

CUTTING OIL NO. 2:-

CHLORINATED CUTTING OIL:-

SULFURIZED CUTTING OIL

FORMULATION OF CUTTING OIL BASE

OTHER FORMULATIONS OF CUTTING OIL

STABLE AQUEOUS CUTTING OIL

CUTTING OIL FOR CUTTING EDGES, DRILLS ETC.

FORMULA 7 IS MANUFACTURED IN THE SAME, BUT HOT WAY.

HARD WATER STABLE CUTTING OIL

ROSIN SOLUBLE CUTTING OIL

MANUFACTURING PROCESS OF CUTTING OIL

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CUTTING OIL

PLANT LAYOUT

ANOTHER MANUFACTURING PROCESS FOR CUTTING OIL

MANUFACTURING PROCESS FOR CUTTING OIL

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CUTTING OIL

CUTTING METHOD AND CUTTING OIL

(A) WATER-INSOLUBLE CUTTING OIL OF THE METHOD

(B) SOLUTION OF THE METHOD

HIGH PERFORMANCE CUTTING FLUIDS FOR GLASSY, CRYSTALLINE OR AGGREGATE MATERIALS

EXAMPLES

SOLUBLE-OIL CUTTING FLUID

EXAMPLE

TWO SOLUBLE OIL FORMULATIONS WERE PREPARED BY MIXING THE FOLLOWING COMPONENTS:

PREPARATION OF CUTTING FLUIDS

CORROSION TEST

EMULSION STABILITY TEST

MICROBIAL DEGRADATION TEST

GLASS CUTTING FLUID

EXAMPLE 1

EXAMPLE 2

CUTTING FLUID, METHOD FOR PRODUCTION AND METHOD FOR CUTTING

EXAMPLE 1 AND COMPARATIVE EXAMPLE 1

ADDRESSES OF PLANT & MACHINERIES SUPPLIERS

MIXING KETTLES

TANKS

LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT

ADDRESSES OF RAW MATERIAL SUPPLIERS

PETROLEUM SULFONATE

FATTY ACID

MINERAL TURPENTINE OIL

GLYCEROL MONOSTEARATE

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)

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