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Content archived on 2024-05-14

Potential strategies for reducing particulate emissions during dry machining

Objective


The use of cooling lubricants in metal cutting operations is coming under incre asingly critical scrutiny in manufacturing companies. In 1996, for example, the volume of lubricant (water miscible and water immiscible) requiring disposal, totalled 580.125 t (tonnes) /BfW 96/ in Germany alone. The cost of disposal flu ctuated, depending on the degree of contamination, between 80 ECU/m3 and 1500 E CU/m3 in Germany. Additionally, investigations have revealed that 30% of all se rious skin diseases in the metal working sector are attributable to the use of lubricants /BG 93/. Possible solutions to these problems range from the optimis ation of the use of lubricant through strategies to minimise the quantity of lu bricant, to total abandonment of the use of media of this nature in dry machini ng operations. Dry machining operations, particularly those performed on bri ttle materials, cause dust like particles to be released. In contrast to wet ma chining operations, these particles are not picked up by the lubricant and carr ied away but can spread out freely from the point at which they originated. In terms of Safety at Work, these emissions represent a significant health risk. I n addition to the effects on the human body, which range from nuisance to cance r, adequate account must be taken of the danger of dust explosions and fires. E xploratory investigations show that peak concentrations of up to 400 mg/m3 (ins ide the amchine) can occur when casting materials are milled (material machined : GG25). However, the maximum permissible limit for inert metallic dust which h as not been classified as hazardous is currently 4 mg/m3 (inhalable proportion outside the machine) /MAK 97/. It is essential, therefore, to implement proc ess measures involving both the process and the machining facility, to collect any emissions released and to reduce the emission level. Starting from the prob lems outlined above, the project envisaged will encompass the development of po tential strategies for reducing particulate emissions and the associated enviro nmental pollution during dry machining operations conducted on casting material s. Based on the characterisation of resultant emissions the potential for their reduction by precautionary measures as a substitute for or in addition to post operational measures will be investigated. The investigations envisaged thus r elate to Item 2.2.3.2 integrated Technologies for the Limitation of Emissions in the Environment and Climate Programme of Work of the European Commission.

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Coordinator

MIKROMAT Werkzeugmaschinen GmbH & Co.KG
EU contribution
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Address
Niedersedlitzer Strasse
01239 Dresden
Germany

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Participants (3)

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