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.

Issue Section:
Technical Papers
Keywords:
liquids, cutting, machining, aerosols, environmental factors, jets
Topics:
Aerosols, Cutting, Disks, Fluids, Machining, Flow (Dynamics), Rotation, Turning
1.
Bienkowski, B., 1993, “The True Coolants and Lubricants,” Manuf. Eng., March, pp. 90–99.
2.
U.S. Department of Health and Human Services, 1998, Occupational Exposure to Metalworking Fluids, DHHS (NIOSH) Publication No. 98–102, January.
3.
Greaves
,
I. A.
,
Eisen
,
E. A.
,
Smith
,
T. J.
, and
Pothier
,
L. J.
,
1997
, “
Respiratory Health of Automobile Workers Exposures to Metal-Working Fluid Aerosols: Respiratory Symptoms
,”
Am. J. Ind. Med.
,
32
, No.
5
, pp.
450
–
459
.
4.
Robin, T., Seixas, N., Franzblau, A., Burge, H., Abrams, L., and Minick, S., 1994, Respiratory Effects of Machining Fluid Aerosols, Final report to the UAW-GM Occupational Health Advisory Board.
5.
Yue, Y., Sutherland, J. W., and Olson, W. W., 1996, “Cutting Fluid Mist Formation in Machining via Atomization Mechanisms,” Design for Manufacturing and Assembly (ASME), DE-Vol 89, pp. 37–46.
6.
Bell, D. D., Chou, J., and Liang, S., 1999, “Modeling of Cutting Fluid Effect on Shop Floor Environment,” STLE Tribol. Trans.
7.
Bayvel, L., and Orzechowski, Z. 1993, Liquid Atomization, Combustion: An International Series, Taylor & Francis.
8.
Matsumoto, S., and Takashima, Y. 1978, Atomization Characteristics of Power Law Fluids by Rotating Disk, ICLAS-78, pp. 145–150.
9.
Currie, I. G., 1993, Fundamental Mechanics of Fluids, Second Edition, McGraw-Hill Inc., p. 82.
10.
Preziosi
,
L.
, and
Joseph
,
D. D.
,
1988
, “
The Run-off Condition for Coating and Rimming Flows
,”
J. Fluid Mech.
,
187
, pp.
99
–
113
.
11.
Dombrowski
,
N.
, and
Johns
,
W. R.
,
1963
, “
The Aerodynamic Instability and Disintegration of Viscous Liquid Sheets
,”
Chem. Eng. Sci.
,
18
, pp.
203
–
214
.
12.
Strutt, J. W., and Rayleigh, B., 1937, The Theory of Sound, London, Macmillan and Co., Limited.
13.
Lefebvre, A. H., 1989, Atomization and Sprays, New York Hemisphere Pub. Corp.
Copyright © 2001
 by ASME
You do not currently have access to this content.