Effect of Friction Testing of Metals on Particle Emission

Metallic particles emitted during manufacturing processes can represent a serious danger for occupational safety. The mechanisms responsible for these particle emissions include two- and three-body frictions; Moreover, such particles can also be emitted during several other processes, including mechanical braking. To be in a position to devise ways to reduce these particle emissions at the source, it is important to know their size, quantity, and distribution, as well as the relationships between operating conditions and particle emissions. This article investigates nanoparticle and microparticle emissions during two friction tests: one (setup 1: pin in rotation only) simulates the friction occurring during mechanical braking actions, and another (setup 2: pin in rotation and translation) simulates the friction taking place at the tool-workpiece interface during metal cutting processes. The materials tested were aluminum alloys (6061-T6 and 7075-T6), and the pin used was a carbide cylinder. Particle emission was monitored using the Scanning Mobility Particle Sizer (SMPS) for nanoparticles, and the Aerosol Particle Sizer (APS) for microparticles. It was found that friction produces more nanoparticles than microparticles, and that total particle emission can be reduced by operating at low or at high sliding speeds.