Abstract
This paper presents an analytical model for the prediction of shop floor aerosol concentration and size distribution due to the spinoff of cutting fluid from a rotational workpiece in a turning operation. Based on atomization theory and principles of fluid motion, the model analyzes the generation of cutting fluid aerosol associated with the rotary disk and liquid sheet formations on the workpiece surface. In coupling with fluid flow rate analysis and Rosin and Rammler distribution model, the airborne particulate concentration and size distribution are expressed in terms of fluid properties, fluid application conditions, and machining process parameters. Experiments were performed with the use of light scattering particle measurement device 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.