Cutting Fluid Mist Formation via Atomization Mechanisms
 
 

Yan Yue | PhD | 2000

Abstract:

Cutting fluid mist is becoming an increasing concern for manufacturers as additional information is obtained on the health risks that it poses. An effective strategy to minimize the cutting fluid mist requires a fundamental understanding of cutting fluid mist formation mechanisms and the underlying process conditions affecting mist formation. In this dissertation, analytical models are developed to characterize mist formation mechanisms, including atomization and vaporization/condensation mechanisms. The prediction of the fluid droplet size and distribution, as well as vapor and mist concentration is a central theme of this work.

First, atomization models are developed to predict the mean drop size and the drop size distribution of the cutting fluid mist under the various machining process conditions. For a jet impinging on a stationary workpiece, two types of droplet formation mechanisms (edge-breakup and splattering) are considered. It is demonstrated that splattering is the dominant mechanism for mist formation in this case. Many machining processes involve the use of rotating elements, e. g., turning-workpiece and milling-cutter, a model is developed to describe the atomization mechanism associated with the turning process.

In addition to the atomization mechanism, attention is also focused on mist formation via an vaporization/condensation mechanism. Fluid vaporization under ambient temperature conditions is examined. A theoretical model to predict the vapor production by jet impinging boiling is developed.

Finally, a model describing the dynamic droplet distribution and mass concentration versus time is developed and integrated with the other models to form a complete model for mist formation in turning. The complete model can be used to predict the mist characteristics that would be obtained via experimental methods. It will be seen that model predictions/simulations agree well with the experimental results.

The models may be used to identify techniques for producing heavier mist droplets and reducing the amount of mist generated, thus reducing the health hazard. These techniques may include new cutting fluid formulations and application strategies.

If you have any comments or suggestions please e-mail jwsuther@mtu.edu.