Quaker final presentation
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Transcript of Quaker final presentation
Method Development & Fluid Performance in the Machining of 4140 Steel
ARIE GARZON, NAZERKEM ITYBAYEVA, RICHARD MASTRORILLI
Project Scope
PROBLEM DESCRIPTION & PROJECT REQUIREMENTS
Problem DescriptionThe focus of the project is to develop a testing method to determine the quality of a machining coolant
Three fluids provided to test:◦ Quakercool 750-TP
◦ Quakercool 2776
◦ Quakercool SH-720
Project RequirementsUse the experiment to test the quality of three different coolants.
Correctly identify the good quality fluids from the poor quality fluids
Test needs to have the ability to be duplicated by Quaker’s lab testing facilities.
Thread cutting must be performed using a vertical CNC, not a horizontal turning machine
Project Solution & Procedures
METHODS, MACHINING, AND ANALYSIS PROCESS
FluidsFluid mixed would be to a 10% concentration as specified by Quaker
Hardness of 125 ppm also specified and was achieved by mixing 50% distilled water with 250 ppm tap water
Concentrations would be verified by using a refractometer
Project SolutionA tapping procedure was selected
Torsional force data recorded using a dynamometer
A go/no-go gage used to verify quality
Average torsional force at each interval would be calculated
Project SolutionThe data can be regressed to find a potential linear relationship
The hope is that the linear relationship leads to rate of tool wear
A difference of mean test will then be used to statistically determine the significance of data
Null hypotheses states difference of mean between samples is equal to 0; (x1 – x2 = 0)
ProcedureThe machine selected is a HAAS VF 2-SS
Test consists of two blocks 4140 steel blocks
One 4”x4” steel block is attached to a dynamometer
A larger block 4”x8” is held by a table vice
ProcedureThe process first machines 12 holes in the small block using the machining process (listed on next slide)
36 holes are then machined into the larger block
Machining ProcessSpot Drill to 14mm diameter at a speed of 485 rpm and a feed of 4.2 ipm
Peck Drill through 9.8mm diameter at a speed of 693 rpm and a feed of 6.0 ipm
Ream through to 10.2mm diameter at a speed of 285 rpm and a feed of 5.1 ipm
ProcessA TiCN Plug Tap M12x1.75 is used for the tapping procedure
Tapping is performed to a depth of 1 inch at a speed of 242 rpm and a feed of 16.7 in/min
Three holes are first tapped in the larger block
ProcessA hole is then tapped in the smaller block
Force and moment data is recorded through the dynamometer each time a hole is tapped in the small block
A full test is comprised of 12 cycles (48 holes)
Each test yields 12 sets of torque data
The test is performed twice for each fluid
Each test utilizes a new tap
Results
DATA REGRESSION AND STATISTICAL SIGNIFICANCE
Data Analysis- Coolant 1Regression of average torsional values of QC 750-TP
P-value of .032
R-Sq value of 38.3%
50403020100
105
100
95
90
85
80
S 5.69291
R-Sq 38.3%
R-Sq(adj) 32.2%
Trial
Co
ola
nt
1
Fitted Line PlotCoolant 1 = 81.49 + 0.2968 Trial
50403020100
105
100
95
90
85
80
S 7.04671
R-Sq 16.0%
R-Sq(adj) 7.6%
Trial
Co
ola
nt
2
Fitted Line PlotCoolant 2 = 87.96 + 0.2033 Trial
Data Analysis- Coolant 2Regression of average torsional values of Quakercool 2776
P-value of .198
R-Sq value of 16%
Data Analysis- Coolant 3Regression of average torsional values of Quakercool SH-720
P-value of .304
R-Sq value of 10.5%
50403020100
100
95
90
85
80
S 6.57234
R-Sq 10.5%
R-Sq(adj) 1.6%
Trial
Co
ola
nt
3
Fitted Line PlotCoolant 3 = 90.28 - 0.1490 Trial
Data Analysis
75
80
85
90
95
100
105
110
4 8 12 16 20 24 28 32 36 40 44 48
Ave
rage
To
rsio
nal
Fo
rce
(in
lb)
Trial
Average Torsional Tapping Forces
QC 750-TP Quakercool 2776 Quakercool SH-720
Data AnalysisFirst t-test (coolant 1 and 2):
QC 750-TP and QC 2776; 95% CI (-10.09, 2.01); P-value .18
Fail to reject null hypothesis
Second t-test (coolant 1 and 3):
QC 750-TP and QC SH-720; 95% CI (-2.94, 8.55); P-value .32
Fail to reject null hypothesis
Third t-test (coolant 2 and 3):
QC 2776 and QC SH-720; 95% CI (.91, 12.78); P-value .026
Reject the null hypothesis
Interpreting the resultsThe only statistically significant difference in mean is between QC 2776 and QC SH-720
The only coolant that has a significant chance of being represented by a linear relationship would be QC 750-TP due to its p-value of .032, R-Sq value of 38.3%, and visual inspection
Future development of the experiment:
Lack of tool wear is believed to have caused an overall lack of linear trends
Finding end of life of the taps will shed more light on the trend of torsional force as the tool wears