Air Quality 2

Agenda

 Mist models - Introduction

 Predicting cutting fluid mist
 Experiment
 Atmospheric aerosols
 Introduction

 Sources
» Cutting fluid
– Condensation
– Atomization /
Condensation
– Splashing & Drag
out processes
» Atmospheric
 Condensation - 1

 Heat generated in
the workzone may
result in cutting
fluid jet boiling
and evaporation.
 Condensation - 2

 Estimate evaporation rate through the heat

flux prediction.
» Analytical Techniques
– Closed form solutions of temperature distributions
(temporal & spatial) due to conduction and
convection with a moving heat source
» Experimental validation
 Atomization - 1

Motivation
 Relationship between drop size and
droplet suspension
 drop size distribution
» deposition in the various regions of the human
respiratory tract.
 Atomization - 2

 Fluid jet impinging a

stationary flat plate
» Boundary layer
» Splatter
 Atomization - 3

Modes of liquid film

disintegration:
 Drop formation mode
 Ligament formation
mode
 Splatter
 Atomization - 4
- Rotating Workpiece:
Wave development followed by drop separation
mv 2
 2 r s-surface tension force
2
 Splashing & Dragout

 Splashing
 Dragout
» Ligament formation
» Breakup modeling
– Force balance
 Mist Control Strategies
• Enclosing the machine tool
- restrict to access to the machine tool

• Using air filters and mist collectors

- expensive to maintain and operate

• Adding antimisting agents to cutting fluid

- be effective in suppressing mist formation
- added cost
 Experimental Investigation
Purpose:
• Examine the underlying process conditions that
affect the mass concentration level of cutting fluid mist
• Identify significant factors to lead to modifications in the
machining process as an alternative solution for
minimizing cutting fluid mist

Underlying process:
Turning
 Experiment Setup

Lathe: Emco Compact

Nozzle sizes: 0.3175 cm
and 0.635 cm
Fluid flow rate: 3.4 l/min
Mass concentration measurement:
Aerosol monitor
 PM10 Experiment Design

1
Two level 26fractional factorial design

Investigated variables:
• Spindle speed
• Workpiece diameter
• Nozzle diameter
• Cutting fluid oil concentration
• Sampling locations (X, Z)
Variable Levels for PM10
Experiment
Sampling Probe Location
Mass Concentration Measurement
 PM10 Experiment Analysis
Significant effects:

• Spindle speed
- Increase speed produces a mechanical energy
and Lead to the formation of droplets.

• Workpiece diameter
- A large diameter results in a great surface velocity

• X-location
Variable Levels for PM2.5
Experiment
 PM2.5 Experiment Analysis

Significant effects: only spindle speed

• Fine particles are uniformly distributed in

the air around the machine tool.

• A larger workpiece diameter results in more

coarse particles, but has little effect on the
number of fine particles.
 Summary of Experiments
• Spindle speed is the most significant variable affecting
PM10 and PM2.5 mass concentration.

• Workpiece diameter has a significant effect on PM 10 but

not on PM2.5 mass concentration.

• X-location is significant for PM10 but not for PM2.5 mass

concentration.

• Attention should be focused on high speed machining

operation (turning, face milling, and boring)
Atmospheric Aerosols

 Relevance in manufacturing

 Characterization
 Atmospheric Aerosols - 1

 Aerosols impact the chemistry and physical

processes of the troposphere in several
ways:
» Cloud condensation nuclei (CCN), they directly
impact the earth's radiative budget via light
scattering
» Serve as sites for heterogeneous reactions.
 Atmospheric Aerosols - 2

Aerosol > 1microns

serve as ice nuclei, and may contain the
bulk of the aerosol mass;

Submicron aerosol become CCN in the

ambient atmosphere and are efficient light-
scatterers.
 Atmospheric Aerosols - 3

 Need - Composition of aerosols as a

function of size
» Measurement of sulfate and soluble organics as
a function of aerosol size
» Example:
– Quantify the fate of emitted anthropogenic
and biogenic sulfur compounds
 Aerosol Chemistry

 Heterogeneous interaction of
gaseous molecules with aerosol
particle surfaces
 Characterization of atmospheric
aerosols, mainly in the free
troposphere.
NOAA
 What happens?

 Radiation scattering
» Natural
» Human activity (industry)
– Sulfur emissions from various sources

Re. National Oceanic and Atmospheric Administration

Global Sulfur Emissions