Cutting fluid aerosol generation in turning operation

This study develops a set of quantitative models to predict the generation rate of shop floor aerosol resulting from the use of cutting fluid in the turning process. Two primary mechanisms of fluid aerosol generation are considered: spin-off and splash. Based on the description of fluid motion and the principle of atomization, the airborne particulate concentration and size distribution are expressed in terms of fluid properties, fluid application conditions, and machining process parameters. A series of experiments were performed to calibrate and validate the analytical models. Under various fluid flow rates, spindle speeds, and workpiece sizes, experimental data have shown reasonable agreement with model predictions. The predictive models developed in this paper can be used to analyze fluid mist exposure levels, and to facilitate the optimization and control of cutting fluids in meeting given environmental standards.