Cutting Fluids

Effects on Ecology
 Background and Motivation
• More than 100 million
gallons of cutting fluid is
consumed annually in the
developed countries

• Environmental
degradation, Health
Hazard

• Need to reduce cutting

fluid use
Background and Motivation
Cutting Fluids

Oil Based Chemical

Straight Oils Emulsions Synthetics Semi-synthetic

+ Additives + Additives + Additives + Additives

Additives: Organic (Aromatic hydrocarbons)

Inorganic (Chlorine, Sulphur, Phosphorus)
Biocides, Odorants
 Introduction

Functions of Cutting Fluids

• Heat transfer
- Tool wear & life
- Dimensional accuracy

• Lubrication

• Chip flushing, corrosion prevention, cleaning

 Introduction

Questions addressed

Why use fluid?

Dimensional error
due to heat transfer

How (health hazard)?

Exposure to mist
 Dimension Error - 1
• How we define
surface error in
the boring
experiments:-

Out of
roundness
Surface error

Angular position
 Dimension Error - 2

• Single tool boring of

aluminum cylinders

• Radial, tangential and

axial forces cause
deformation
Role of Fluids on Heat Transfer

Boring experiments:

Sources of dimensional
error:
• Thrust force
• Heating effects
 Heat Transfer Model
w d2  dz2 - 2 H + g(z,t)/k = wq/t
g(z,t): heat source strength, k: Thermal conductivity,
H: Ratio of convection coefficient and thermal
conductivity.
Temperature History
Surface Error
 Cutting Fluid Mist

Mist: formed by condensation or

atomization -- size range from submicron to
20 microns.

Such aerosols are generated during

machining operations such as drilling,
milling, boring, drilling and turning.
 Health & Env. Effects - 1

• NIOSH:-1.2 million are exposed to

cutting fluids [Hands et al., 1996]

• Bacteria / fungi in cutting fluid

produce toxins [Thorne et al., 1996]

• Mist collectors are sometimes

ineffective [Leith, 1996]
Health & Env. Effects - 2

• Airborne particulate from 5 mg/cu. m to

0.5 and 0.1 mg/cu. m (UAW and OSHA)

• Aerosols from PM10 to PM2.5 and

PM1.0 (EPA)
 Mist in Machining

Modes of mist formation

(1) Liquid film disintegration

- Low velocity
- High velocity
of fluid impact on workpiece

(2) Evaporation / Condensation

 Mist in Machining

• Experiments
with mist
formation
during turning
 Liquid Film Disintegration
Thickness varies inversely
Boundary Layer Theory with distance and
Reynold’s number

Flowing Fluid Film Thickness

Mean droplet diameter of the same

order of magnitude as film thickness
 Turbulent Splatter
Empirical correlations

• Splatter occurs when the dimensionless group

proportional to the Weber number and inversely
proportional to the nozzle diameter exceeds 2120

• The fraction splattered can also be predicted

(2.5% for high values of the dimensionless
parameter)
 Drop Mode
Drop diameter (maximum) can be predicted with
good experimental correlation by considering
equilibrium of surface tension and centrifugal
forces.
 Ligament Mode
At high flow rates, empirical relations predict ligament
diameter, which is related to the drop diameter

Ligament diameter

Drop diameter
 Evaporation / Condensation

• Supersaturated vapor (P0/Ps>1) will

recondense

• The rate of droplet growth is proportional

to supersaturation and drop size and
inversely proportional to temperature
 Mist Droplet Motion
• For very low flow rates (Re < .001), small
particles (diameter < 0.1 micron) experience
Brownian motion

• At higher flow rates and larger particle sizes,

the spatial and temporal aerosol distribution
is a function of gravity and drag
 Assignments

1. What have we discussed? (Please write a short resume,

1 page)
2. Effect of using Cutting Fluid on surface error in boring
operations (1/2 page)
3. Describe the mechanism of mist formation (1 page)