Cutting Fluid Aerosol Generation due to Spin-off in Turning Operation: Analysis for Environmentally Conscious Machining

Abstract

This paper presents an analytical model for the prediction of shop floor aerosol generation rate and particulate size distribution due to the spin-off motion of cutting fluid from a rotational workpiece in a turning operation. Based on the theory of atomization and principles of fluid motion, the model analyzes the generation of cutting fluid aerosol associated with the formation of rotating cylindrical peripheral disk and liquid sheet on the workpiece surface. In coupling with fluid flow rate analysis and Rosin and Rammler distribution model, the airborne particulate generation rate and size distribution are expressed in terms of fluid properties, fluid application condition, and machining process parameters. Experiments were performed with the use of the light scattering particle measurement devices to calibrate and verify the analytical models. Under various fluid flow rates and workpiece rotational speeds, experimental data have shown reasonable agreement with model predictions. The predictive models developed in this paper can be used as a basis for human exposure and health hazard analysis. It can also facilitate the control and optimization of the use of cutting fluids in achieving a balanced consideration of process productivity and environmental consciousness.