UNIT I

INTRODUCTION
A. Background of study
Metal cutting process is a process that use to deform a metal material by cutting
process. Cutting process use some cutting tool like endmill cutter and chisel cutter that
the quality of work piece is so effected by the cutter (cutting tool), (azwar, 2013)
investigated that a bad work piece is made by a dysfunction cutter, in terms of material or
in terms of geometry (shape and angle of chisel).
Chisel damaged caused by so many factor, like rubbing between material and
chisel made a high temperature chip that make chisel blunt. Cutting speed, length and
deep of cut is make an effect to the temperature of chip. If rubbing between chip and an
active cutter area was so high it will make the temperature high too, and it will decrease
the cutter life time. Thats why coolant is so important to cooling down the temperature in
machining process.
A conventional cooling process isnt effective anymore for a stronger material
because the process is need a long time. (Azwar, 2013) Investigated in a hard metal
cutting process, heat that made by friction of work piece and cutter will be higher so
conventional cooling process isnt effective anymore.
A high preasure cooling process is a solution to make an effective cooling
process. The high preasure that sprayed from noozle could reach the active chisel area
that have the most high temperature, and automatically it could decrease the chance of
blunt to the cutter and will increase the lifetime of the cutter and it is usefull to control
the current chip, we also could increase the cutting speed (Helmy). (Mazurkiewicz et al.
1989) investigated that cooling process with high preasure could decrease scrape
coefficient between chip and cutter main area, and will decrease cutting force and will
decrease the cutter lifetime.
B. Research Question
Is the high preasure cooling process, could decrease the cutting forces, roughness
surface, and the blunt to the cutter. Than conventional cooling process in traditional
machining process
C. Purpose of study
To knowing how much cutting forces, workpiece and cutter temperature, chance
of blunt, and surface roughness could decrease by using high temperature cooling
process in traditional machine process.
1|High Preasure cooling process

D. Significance of the study

As a reference for another research, for developing a knowledge about high
preasure cooling process in machining process. And as an information to increase the
quality of workpiece.

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UNIT II
LITERATUR RIVIEW
A. Machining Process
Machining is the broad term used to describe removal of material from a
workpiece, it covers several processes, which we usually divide into the following
categories:

Cutting, generally involving single-point or multipoint cutting tools, each

with a clearly defined geometry.
Abrasive processes, such as grinding.
Nontraditional machining processes, utilizing electrical, chemical, and
optimal sources of energy.

It is important to view machining, as well as all manufacturing operations, as a

system consisting of the workpiece, the tool and the machine. The introduction topic in
this section covers primers on topics like mechanics & shear bending in machining, and
heat in machining. The traditional machining includes primers on turning, milling,
drilling, and grinding. It also includes computer applications which are being supported
by the primers. The non traditional machining includes primers on the topics like ECM,
EDM, AFM, USM. (www. mfg.mtu.edu/cyberman/machining.html)
In the machining process, metal cutting with cold condition could stop the cutter
blunt, reduce cutting temperature, and finaly it could increase cutter lifetime and surface
of the workpiece. So use cooling fluid in machining process is so recommended, so there
is no change of structure (Rochim)
B. Lathe Cutting tool
Tool Geometry. For cutting tools, geometry depends mainly on the properties of
the tool material and the work material. The standard terminology is shown in the
following figure. For single point tools, the most important angles are the rake angles and

Pictures
the end and side relief
angles.1. Lathe cutting tool Geometry
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The back rake angle affects the ability of the tool to shear the work material and
form the chip. It can be positive or negative. Positive rake angles reduce the cutting
forces resulting in smaller deflections of the workpiece, tool holder, and machine. If the
back rake angle is too large, the strength of the tool is reduced as well as its capacity to
conduct heat. In machining hard work materials, the back rake angle must be small, even
negative for carbide and diamond tools. The higher the hardness, the smaller the back
rake angle. For high-speed steels, back rake angle is normally chosen in the positive
range. There are two basic requirements for thread cutting. An accurately shaped and
properly mounted tool is needed because thread cutting is a form-cutting operation. The
resulting thread profile is determined by the shape of the tool and its position relative to
the workpiece. The second by requirement is that the tool must move longitudinally in a
specific relationship to the rotation of the workpiece, because this determines the lead of
the thread. This requirement is met through the use of the lead screw and the split unit,
which provide positive motion of the carriage relative to the rotation of the spindle.
C. Mill Cutting tool
A milling cutter is a cutting tool that is used on a milling machine. Milling cutters
are available in many standard and special types, forms, diameters, and widths.The teeth
maybe straight (parallel to the axis of rotation) or at a helix angle. The helix angle helps a
slow engagement of the tool distributing the forces .The cutter may be right-hand (to turn
clockwise) or left-hand (to turn counterclockwise).The figure shows a typical end milling
cutter.
Some of the terms used to identify the major features of a milling cutter are given in
the figure.

Pictures 2.
4 | H i g h P r e a s u r e cEndmill
ooling process

D. Cutting Condition
There is there variable for every traditional machining process it is deep of cut,
cutting speed and feeding motion. To get the god product in term geometry, tolerant that
we want, we need to notice some of trouble factor (Rochim)
E. Cutter Element

Body : is a part of cutter that formed to be edge of cut, or place of cutter

Shank : is a part that use to paired with the machine
Tool bore : that is a hole in the cutter that can be paired with the main
spindle of machine

F. Blunt and the damage of cutter

Life time of cutter isnt always effected by geometry of cutter, every factor of
machining process,
Kind of Material of workpiece
Cuting condition
Cooling process
Kind of machining process
Blunt is a phenomenon that often happen in engginering process. Blunt isnt the
only one process, but so many process that could be happen in common or one by one.
We could read the complicit of blunt to know the variable of blunt, like hardness,
ductility, elasticity, tensile strength, stress, and surface structure that meet, like
geometry,temperature etc.
G. Cooling Process
Generally, cooling fluid is use to cooling and lubricating, cooling fluid could
clean chip that patched in the cavity between an abrasive powder so will guarantee the
forming process of chip. High temperature that happen in outer surface can be reduced so
that will not destroy the structure of metalografi material product.

5|High Preasure cooling process

Cooling is so needed to reduce the blunt chance of cutter. Another income form
cooling fluid is.

Reduce the temperature incrase

Me a better surface of workpiece
Clean the cutter from the chip
Avoid the corrosion
Reduce the lost of heat that made by friction
Increase the lifetime of cutter
Produce low force cutting

E. Cooling Method
Choose the usage of cooling is make an effect to the cutter or machining process.
Way of cooling process that usually use is.

Manual; if the machine dont have the cooling system, so cooling system
is use with manual way. Like using brush or spray to be a media of coolant
Disbursed; cooling fluid disbursed to the active area of cutting using
noozle, and the coolent is pumped from the coolant tank on machine
Atomized; coolant is sprayed to the active area of cutting like an atom
particle
Pressed trough the line of the cutter; coolant is flowed trough the line of
cutter
High preasure cooling process; cooling method that cooling fluid was
sprayed by noozle to the workpiece with high preasure. Cooling fluid
sprayed to the hottest point. With preasure 400kN/m 2 or 4 bar until 130
bar.

Another research has investigated that the potential of using high preasure cooling
process is better than conventional cooling process. Jet is use to separate chip with
upside of cutter. Income of pointing the jet to the side of cutter is we coul control the flow
of the chip, an combined with decreasing workpiece and cutter temperature.

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Kamruzaman investigated that this method isnt just turndown the

temperature, but it will save 50% of coolant usage. The purpose of using high
preasure cooling process is:

Increase the life time of cutter

Cooling process by way cooling with high process so good
to applied in cutting process to stop the blunt rate of cutter

Picture 4. Cutter withoun coolant

Cutter with high preasure cooling process

Protect from corrosion

Cooling fluid is one part of cutting process that minimize
the corrosion.
Improve quality of workpiece surface
High preasure cooling process could to clean a fragment of chip,
that patched to the surface of workpiece when cutting process so
Picture 3. Cooling process with high preasure
(kalpakjian)

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the surface will be better than surface without high preasure

cooling process.
F. Count the current rate
The fluid rate could be counted by reading the different of preasure
technique on that pipe, where to got the different preasure of that pipe made by
sett the different of diameter with another diameter. This method is bernoli law
and the function is.

V
g

= the fluid pressure (pa)

= Density of the fluid (kg / cm3)
= fluid velocity (m / s)
= gravity of the earth

= height of fluid

Pictures 5. Bernoli law Principe

Pitot pipe, orifice plate, venture pipe and flow nozzle use bernoli law. The
Principe is change a little accelerate in the current fluid, so we will got a change
of preasure that we can ne observed.

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UNIT 3

A. The stages of the research can be seen in the flowchart below

START

Literatur Library

Purpose and significance of research

Preparation tools and materials

examination

1. Coolant High pressure

2. Variation nozzle: 0.7 mm, 0.9 mm, 1.2 mm, 1.5 mm
3. Depth of cut: 0.5mm, 1mm, 2mm

Traditional machining process

No
Date Analysis

Conclusion

Finish
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B. Trial tool
Machine and trial tool of these research and the research model will be described
in this part. Machining process was do in lab. Elementary machining process. And date
withdrawal have been done in lab. Deformation Tech. Univ. Syiah Kuala.
a. Traditional lathe Machine
Spec of the machine that used in this research is:
Merk/type
: KNUTH Compass 250/1000B
Production
: Jerman (2011)
Power
: 6,0 kW
Volt
: 400 volt
Frequency
: 50 Hz/3 phasen

Picturs 6. Lathe
b. Coolant pump Machine (Univ. Syiah
Pump machine
kuala) that we use in this reseach is:

Pictures
(univ. syiah
kuala)
Merk 7. Pump
: Panasonic
GP125
Q
: 35 L/min
Hmax
: 30 m
Input model : 220 V / 50 Hz
c. High preasure cooling tool
The principle of high preasure cooling process that used in this research
could we see in picture bellow
Pictures 8. Cooling scheme
10 | H i g h P r e a s u r e c o o l i n g p r o c e s s

Nozzle is the
main component of

this tool, with make a variation 4 nozzle with a different

diameter
0,7 mm, 0,5 mm, 1,2 mm, and 1,5 mm. the shape of nozzle that we use is a cone
nozzle with nozzle material that could strength until 690 bar.

Pictures 9. Nozzle
d. Coolant
Coolant that we use in this research is water soluble oil. Oil that have an
lubricant function mixed with water will make an emulsion fluid that have an oil
particle wth size 5 u/ 8 micron meter will be spread and the light that touch it, will
be deflected, and make the fluid have white color or another color suspended by
fluid that mixed with it.
e. Measuring tool
Microscope measuring is a tool to measure the blunt grow of cutter in the
side that used to cutting the workpiece. And the spec is:
Tool name

: Optic Microscope

Merk

: Olympus

11 | H i g h P r e a s u r e c o o l i n g p r o c e s s

Type

: GX71

Production

: Japan

Zoom

: 5x

Pictures 10. Optic Microscope (Univ. Syiah Kuala)

12 | H i g h P r e a s u r e c o o l i n g p r o c e s s