Increasing attention is being devoted to the airborne emissions resulting from a variety of manufacturing processes because of health, safety, and environmental concerns. In this two-part paper, a model is presented for the amount of cutting fluid mist produced by the interaction of the fluid with the rotating cylindrical workpiece during a turning operation. This model is based on relationships that describe cutting fluid atomization, droplet settling, and droplet evaporation. Experiments are performed to validate the model. In Part 1 of the paper, the emphasis is on model development. In the model, thin film theory is used to determine the maximum fluid load that can be supported by a rotating cylindrical workpiece; rotating disk atomization theory is applied to the turning process to predict the mean size of the droplets generated by atomization; and expressions for both the evaporation and settling behavior are established. Droplet size distribution and mass concentration predictions are used to characterize the fluid mist. Model predictions indicate that the droplet mean diameter is affected by both fluid properties and operating conditions, with cutting speed having the most significant affect. Model predictions and experimental results show that the number distribution of droplets within the control volume is dominated by small droplets because of the settling and evaporation phenomena. In Part 2 of the paper, the cutting fluid mist behavior model is validated using the results obtained from a series of experiments.
With support from the US National Science Foundation and Department of Energy, a global benchmarking study of the status of Environmentally Benign Manufacturing (EBM) has recently been completed. The study [1], completed under the aegis of the World Technology Evaluation Center at Loyola College in Maryland, gathered information on research and development around the world aimed at developing alternative methods for materials processing with the purpose of minimizing toxic material generation and optimizing products and by-products for sustainability and reuse characteristics. The study reviewed the current status of EBM research, development, and applications in the United States, Japan, and Europe with a view towards evaluating the competitive status of US efforts. Information was acquired from the technical literature as well as through visits to industry, national laboratories, universities, etc. One area of focus within the study was the automotive industry. This paper summarizes many of the key findings from the global benchmarking study that relate to the automotive industry and identifies areas that require attention for the future.
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