Size distribution of mist generated during metal machining.

Mist generated by machining processes is formed by three mechanisms: impaction, centrifugal force, and evaporation/condensation. This study characterized the size distribution of soluble and mineral oil mists that resulted from these formation mechanisms. Salient parameters influencing the particle size distributions also were identified. Variables investigated included metalworking fluid and machining characteristics. The size distribution of the mist generated on a small lathe by each mechanism was measured using an Aerosizer LD. For impaction, only the mineral oil viscosity influenced the mass median diameter of the mist. No parameter affected the geometric standard deviation. High-viscosity mineral oil mist had a mass median diameter of 6.1 microns and a geometric standard deviation of 2.0. Low-viscosity mineral oil mist had a mass median diameter of 21.9 microns and a geometric standard deviation of 2.2. The mass median diameter of the mist generated by centrifugal force depended on the type of metalworking fluid, fluid flow, and rotational speed of the lathe. Mass median diameters for low-viscosity mineral oil mist ranged from 5 to 110 microns. Mass median diameters for soluble oil mist varied between 40 and 80 microns. The average geometric standard deviation was 2.4, and was not affected by any parameter. The mass median diameter and geometric standard deviation of the mist generated by evaporation/condensation varied with the type of metalworking fluid. The mineral oil mist and soluble oil mist mass median diameters were 2.1 microns and 3.2 microns, respectively. No machining or fluid parameter was important because the mist size distribution depended on the rate of condensation, coagulation processes, and the dynamics of the apparatus. Using the size distribution data from all three mechanisms, the estimated inhalable, thoracic, and respirable fractions of the total mass generated for each metalworking fluid were 60 percent, 12 percent, and 8 percent, respectively. To minimize exposure to the inhalable mass fraction, the amount of mist generated by centrifugal force must be reduced or the size of the drops generated must be increased. Altering the machining or fluid parameters did not change the mist size distribution and reduce exposure to the respirable mass fraction.