Development of an Imaging System and Its Application in the Study of Cutting Fluid Atomization in a Turning Process

Airborne inhalable particulates in the workplace can represent a significant health hazard, and one of the primary sources of particles is mist produced through the application of cutting fluids in machining operations. One of the principal mechanisms associated with cutting fluid mist formation is atomization. Atomization is studied by applying cutting fluid to a rotating workpiece such as found in a turning process. In order to properly study the atomization mechanism, an imaging system was developed. This system extends the size measurement range typically achievable with aerosol sampling devices to include larger particles. Experimental observations reveal that workpiece rotation speed and cutting fluid flow rate have significant effects on the size of the droplets produced by the atomization mechanism. With respect to atomization, the technical literature describes models for fluid interaction with the rotating workpiece and droplet formation via drop, ligament, and film formation modes. Experimental measurements are compared with model predictions. For a range of rotation speeds and fluid application flow rates, the experimental data are seen to compare favorably with the model predictions.