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This study consisted in investigating parameters that significantly influence the spray efficiency of minimum quantity lubrication in a milling tool with inner channels. An initial experimental approach was used to estimate the oil mist consumption and outlet particle velocities with different inlet pressures, for different shapes of inner channels, without rotation (static part). An experimental versus simulation comparison was undertaken between outlet velocities as a function of inlet pressure. The Reynolds-averaged Navier–Stokes model with the Lagrangian multiphase models was validated by comparing experimental and numerical outlet velocities for different inlet pressures. A numerical rotating tool with inner channels was used with the validated model in the second numerical simulation to analyze the influences of inlet conditions (inlet pressure) based on the tool shape and the rotation velocity, in a dynamic approach. The main objective of the oil mist is to reach the cutting edge (qualifying the minimum quantity lubrication spray efficiency) depending on the inlet conditions (inlet pressures) and the machining configurations (rotation velocities) by analyzing the streamlines of the oil mist particles. The study pointed out the tool design effect combined with its rotation velocity on the oil mist capability to reach the cutting edge. This study offered a trend of parameter sets to provide correct inlet parameters based on machining configurations. At high rotation speed, the inlet pressures needed to be high enough to counter the aerodynamic effects occurred by the tool design.

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine Titanium alloy materials due to their poor machinability, resulting in short tool life. The effects of oil mist and air jet flushing on tool wear in the milling of Ti6Al4 V were investigated at a cutting speed of 300 m/min in this study. Tests with various flushing directions of oil mist and air jet during up, and down-cut were carried out. Tool wear and chip shape were measured and analyzed. As a result of these cutting tests and considerations, it was revealed that up-cut with oil mist flushed from any direction and air jet flushed from the side were desirable, and dry down-cut was also desirable.

Ti6Al4V, which is one of difficult-to-cut metals, is widely used in an aircraft structure, parts of a gas turbine and medical equipment, and hole making operation of Ti6Al4V is needed to fasten the parts. When a conventional drilling by twist drill is applied to hole making of Ti6Al4V, it is very difficult to obtain highly accurate hole in diameter, roundness and inlet - outlet edge quality due to a cutting temperature increase caused by a small heat conductivity of Ti6Al4V. Recently, it is well-known that Orbital drilling, which is also called Circular milling, Planetary drilling or Spiral drilling, is superior to conventional drilling for hole making of Ti6Al4V. The author newly developed a hole making machine to enable orbital motion based on Double Eccentric Mechanism so that an endmill driven by one built-in AC motor can rotate clockwise on its own axis at high speed, simultaneously can revolve counter-clockwise on eccentric axis at low speed (Yagishita, 2015). This paper deals with highly accurate hole making technology of Ti6Al4V by employing the machine and a new type cemented carbide endmill having 6 blades. By supplying oil mist from the tip of endmill using a hole through spindle, it is ascertained that cooling by oil mist is strongly effective in order to improve the deviation of hole diameter and roundness, and also edge quality at inlet and outlet of hole.

This paper explains environment friendly water oil mist spray (WOMS) cooling method which is used to obtain lower cutting temperature and higher lubrication at tool chip interface during Ti6Al4V twist drilling process. WOMS is Ester oil based minimum quantity lubrication (MQL) technique but different than neat oil or straight oil based MQL techniques due to combined application of water and oil. Drilling experiments at maximum cutting speed of 50 m/min and 167mm 3 /s material removal rate (MRR), using a 8mm diameter TiAlN coated solid carbide twist drill are conducted under dry machining and WOMS cooling environment. The effect of WOMS are mainly discussed with different cutting parameters, twist drill geometry and compared with dry cutting conditions. A comprehensive evaluation on the cooling effects of WOMS was carried out by spray characterization and subsequent drilling tests. This work is focused on the combined study of tool wear evolution, drill geometry, quality of machined holes under WOMS cooling environment. Drilling under WOMS condition observed 66% higher tool life than dry cutting environment. Experimental results indicated that drilling under WOMS cooling had better cooling effects, higher tool life, optimum cutting parameters.

Electrostatic precipitators (ESPs) are widely used by machining industries to remove oil mist due to the high efficiency, low pressure drop and low energy consumption. In this paper, the effects of oil mist concentration, relative humidity and oil film thickness on the collection efficiency of ESPs were studied. The experimental results showed that discharge current and collection efficiency both decreased with increasing oil mist concentration, and the collection efficiency of fine oil droplets decreased more obviously than that of large-size oil droplets. When the oil mist concentration increased from 100 mg/m3 to 300 mg/m3, collection efficiency of oil droplets with a size of 0.33 μm dropped from 87.13% to 73.53%, while the efficiency for the droplet size of 1.25 μm only dropped from 90.7% to 84.1%. Increasing the relative humidity caused a considerable decline in discharge current due to the decrease in ion mobility, but an appropriate increase in humidity was conducive to the improvement of collection efficiency. The stable status of oil film thickness on electrode plate was obtained (about 10 μm in the current study), and the stable current density decreased almost 11% due to the oil film. Compared with the oil droplets deposited on the electrode wires, the oil droplets deposited on the plate caused more decrease of collection efficiency of ESPs. The decrease in collection efficiency effected by the electrode plate with oil film was twice that of the electrode wires with oil contamination.

Coalescence filters in applications with high separation efficiency requirements, such as compressed air preparation, usually consist of several layers of nonwoven glass fiber media wrapped around a cylindrical metal support grid. The design of this grid has a crucial effect on gas flow inside the filter and therefore on droplet deposition and liquid transport inside the medium. Experimental studies were carried out with flat filter elements in combination with seven different downstream support grids to investigate the impact of the grids on operating behavior of the filters in oil mist filtration. The grids differed in open area fraction, perforation size and distance and were used in combination with either oleophilic or oleophobic filter media. It was found that the choice of the grid affects liquid transport mechanisms in the media, especially the film formation on the filter rear side of oleophilic filters, thus affecting total pressure loss in quasi-steady state, while impact was less significant for oleophobic media. Separation efficiency was not significantly affected by the choice of grid, while entrainment depended on film coverage of the filter rear side and open area fraction of the grid.

Machining plants are often highly polluted indoor environments with dense oil mist generated from metalworking fluids. Workers exposed to oil mist may suffer serious health problems. General ventilation is often used to dilute the oil mist level below the threshold of health risk. However, it is not easy to organize the flow for ventilating a large machining plant with hundreds of machines in order to effectively remove the oil mist. In order to develop an effective ventilation system, this study validated a computational fluid dynamics (CFD) program with the RNG k-e model at a high Grashof number by using the measured air temperature and contaminant concentration in several locations in a high-ceiling lab with heat and pollutant sources. Next, the validated CFD program was used to develop an improved displacement ventilation system in which air is supplied from the lower parts of the support columns in the plant. With thermal plumes generated by machines and workers, the system formed unidirectional airflow that carried pollutants away from the work area of the factory. The system reduced the oil-mist concentration by more than 70% compared with existing ventilation system. In addition, suspended radiant heaters are recommended for supplemental heating in winter.

Load-independent power losses, namely windage power losses, are of big concern when the gearbox is loaded without oil lubrication. Air and/or oil mist are the fluid medium and should be studied before the addition of oil churning and squeezing losses. In this study, firstly, two dimensional computational fluid dynamics (CFD) approaches are followed to understand the behavior of the medium around the shrouded, rotating spur gear for the 40 teeth geometry of Seetharaman and Kahraman. For the sake of simplicity and fast convergence, periodic boundary conditions are employed with addition of carefully selected turbulence models in ANSYS Fluent 18.2. In the second part, same boundary conditions are applied to three dimensional study for the 23 teeth geometry of Seetharaman and Kahraman. Secondary flows and pressure contours are captured well. Windage power loss calculations are compared with the numerical study of Chaari et al. for different angular velocities for two-dimensions. As the result, qualitative behavior of windage power loss change vs. angular velocities matched well with the literature. Currently, three dimensional single spur gear and spur gear pairs are studied for the calculation of windage power losses. They will be compared with experimental data of Seetharaman and Kahraman.

Bearing failure is one of the major concern in Indian Steel Industries as the failure leads to breakdown of the machine and thereby causes huge production loss. Bearing performance depends on design, selection of bearing type, lubricant and the type of maintenance practice chosen for it. In Steel industries there is not much scope to play for enhancing the bearing performance except good maintenance practice and manoeuvre with the lubricant and lubrication system. It is desired for any lubrication or lubrication system to optimise lubricant consumption without compromising the performance /life of the bearing. There are many systems which can provide lubricant with desired viscosity to the bearings. Grease is sticky, so it gets contaminated quickly. Consumption of grease is a bit higher and it does not help to increase the mill speed. The oil mist lubrication is better than grease lubrication system. But it has the problem of atomise oil droplet mix with air which creates foggy and unhealthy atmosphere in the shop/plant. The Air-Oil lubrication system sends metered quantity of lube oil in the form of oil streak through a distributor, carried by dry compressed air into bearing to lubricate it. The carrier air prevents entry of foreign particle in the lubricant and avoids lube oil contamination. It also helps in reaching the lubricant into the bearing clearance to maintain an oil film and it avoids the direct contact with rolling elements and races. Here in this work an attempt is made to enhance the performance of taper roller bearing of Cold Rolling Mill by implementing Air- Oil Lubrication system.

The main goal of minimum quantity lubrication was to transfer an oil mist in a cutting edge via the inner channel of a cutting tool. But machining inner channels in a tool body provided imperfections on inner channel geometries. These imperfections have an effect on oil particle size making up the oil mist and then were studied in this paper. First, numerical simulations, of the oil mist in the channel were investigated by application of the Navier–Stokes and Lagrangian standard equations by integrating the standard k – ɛ turbulence model implemented in STAR CCM+ commercial software. This analysis showed the importance of maintaining small particle sizes and limiting imperfections which otherwise influence the performance of the micro spray and the effectiveness of lubrication. Experimental study was performed for the characterization of the oil mist in channels. The characteristics of the oil mist were defined as being particle velocities and sizes using optical laser methods and of consumption using the residual static gravimetric method. Comparison between experimental and numerical simulation results in the static validation step provided very good accuracy in terms of oil particle velocities as a function of the inlet pressure. Experimental results have shown the spitting effect at specific configurations as predicted with efficiency in the numerical simulation.

A comparative investigation was conducted on wettable and non-wettable glass-fiber filters to clarify the mechanism(s) leading to flow induced entrainment of oil and to determine the influence of oil concentration and filtration velocity on the rate of secondary droplet production. Entrainment rates from a wettable and a non-wettable glass-fiber filter were measured over prolonged periods of time and with high time resolution by two optical techniques covering the drop size regions of about 0.5–10 μm and 150–2000 μm. The rates were compared with oil drainage patterns recorded over time, and with estimates of the forces required to detach drops by blow-off as compared to drop run-off (drainage) or to form air bubbles in a drainage film. It was found that initially oleophobic (i.e. non-wettable) media underwent a one-time transition in apparent wettability during normal operation, due to a change in drainage behavior from individual drops to a film-like flow pattern of oil. The transition was associated with a temporary increase (“burst”) in entrainment rate. After that, both types of media had steady-state entrainment rates that were comparable within a factor of two and depended mostly on the loading rate of the filter (which in turn determines the drainage rate), but showed little or no at all on filtration velocity. In conclusion, blow-off was ruled out as a mechanism contributing significantly to oil entrainment under the prevailing operating conditions, regardless of media wettability. Secondary droplets are due to fragments from bursting air bubbles, which are formed within the liquid film on the downstream face of the media. The entrainment burst of an initially non-wettable medium is also due to bubbles formed on draining oil drops.

A dielectric barrier discharge (DBD) reactor was fabricated and operated in two steps. In the first step (oil mist collection) oil mist aerosols were collected and in the second step (oil mist-to-gas conversion), without supplying oil mist particles but with supplying only clean air flow, collected oil mist particles were converted to gas species. An aerodynamic particle sizer, a scanning mobility particle sizer system, and a real-time gas analyzer were used to measure particle and gas concentrations at the inlet and outlet of the DBD reactor. The oil mist collection efficiency decreased from 78% to 21% but the oil mist-to-gas conversion efficiency increased from 6% to 95%, with increasing frequency from 1 kHz to 10 kHz. Low frequency caused higher amplitude of oscillating particle movement between the electrodes, resulting in higher collection efficiency. At a higher frequency, more electrons were generated, which resulted in the formation of more reactive oxygen species and thus increased subsequent oxidation. Increased surface temperature of the DBD reactor with higher frequency also contributed to higher oil mist-to-gas conversion efficiency. The DBD reactor can be applied to reduce oil mists generated in metal working and cooking processes.

In order to improve a refrigeration system’s energy efficiency, the separation efficiency of its oil separator should be improved. To do so, we turned to nature for inspiration. A Namib Desert beetle collects water in fog by using its skin, which combines hydrophilic and hydrophobic surfaces. Inspired by nature’s design, we applied a surface with oleophilic and oleophobic patterns to an oil separator used in a refrigeration system. In order to make the oil separator, an appropriate design was established using computational fluid dynamics. A cyclone-type oil separator was produced with an oleophobic-treated surface on its lower cup. The efficiency of the treated surface of this oil separator was tested with an open-type experimental setup using an oil mist generator. To obtain conditions similar to those of a refrigeration system in the open-type experimental setup, the oil particle diameter and working fluid pressure were set to yield a Stokes number similar to that of oil particles in the oil separator of the refrigeration system. The oil separator with the treated oleophilic–oleophobic surface improved its oil separation efficiency by 1.67% and its pressure drop by 2.48% compared to a conventional cyclone-type oil separator.

Liquid entrainment from coalescence filter media—i.e. flow induced “blow-off” of previously deposited oil—in the form of droplets is poorly understood, for one because the generated spectrum is very wide and difficult to characterize with temporal and size resolution, especially for very large drops which carry most of the mass. Such filters operate at much lower flow rates than classical demisters, often in vertical orientation, with much finer geometries, and gravity plays no direct role for entrainment. We present a novel combination of four measurement techniques used to capture the entrained oil drop spectrum from filters during operation in the size range of 0.01–2400 µm. The diameter range below 10 μm combines two established real-time methods including an electrical mobility particle spectrometer (EMPS; This measuring system was applied to two representative types of glass microfiber media operated with oil mist generated from compressor oil, in order to characterize time resolved drop formation rates and spectra in the range of nanometers to millimeters. Wettable and non-wettable filter media were found to show similar entrainment characteristics, each with multi-modal drop spectra having two pronounced peaks in the ranges of 1–2 μm and 200–300 μm, respectively. During steady-state operation both modes were generated quasi-continually, the large drops at the rate of a few drops per hour and cm 2 of filter surface, the micron size drops 10 3 –10 4 times more frequently. Available indirect evidence suggests the same underlying entrainment mechanism for both types of fibrous media, namely the break-up of air bubbles formed periodically on the oil that drains on the downstream filter face. Direct detachment (blow-off) of large drops is unlikely at the prevailing operating conditions.

Biodiesel run engines are gaining popularity since the last few years as a viable alternative to conventional petro-diesel based engines. In biodiesel exhaust the content of volatile organic compounds, oil mist, and mass of particulate matter is considerably lower. However, the concentration of oxides of nitrogen (NOx) is relatively higher. In this paper the biodiesel exhaust from a stationary engine is treated under controlled laboratory conditions for removal of NOx using dielectric barrier discharge plasma in cascade with adsorbents prepared from abundantly available industrial waste byproducts like red mud and copper slag. Results were compared with gamma-alumina, a commercial adsorbent. Two different dielectric barrier discharge (DBD) reactors were tested for their effectiveness under Repetitive pulses /AC energization. NOx removal as high as 80% was achieved with pulse energized reactors when cascaded with red mud as adsorbent.

This paper discusses the cutting temperature and cutting force in end milling difficult-to-cut materials cooled with several types of mists and low-temperature air. The cutting tool was a throwaway end mill with a carbide tip coated with titanium aluminum nitride. The Ti-6Al-4V titanium alloy and AISI D2 hardened steel were used as workpieces. The tool flank temperature and cutting force were measured simultaneously during side milling. The temperature was measured using a two-color pyrometer with an optical fiber. Oil mist and water mist from a mist generator were supplied to the cutting point along with cold air at approximately -27 °C. Compared with dry cutting, the cooling effects of supplying an oil mist and/or cold air were less than for other supply conditions in titanium alloy cutting. However, when water mist was added, the tool flank temperature clearly decreased. The cutting force increased for cases that included water mist. The adhesion of the titanium alloy to the cutting edge of the worn tool was significantly suppressed by supplying water and oil mist with cold air. Tool flank wear also decreased under those lubrication conditions.

This paper compares experimental and numerical simulations of liquid film formation for different rotating velocities of a milling tool. The numerical model used was based on an unsteady Reynolds–Average Navier–Stokes (RANS) formulation and multiphase Lagrangian model for liquid film formation by the droplet impingement model on a solid surface. The details of spray–wall interaction are presented and the model was used to simulate the liquid film formation in the Micro-Quantity Lubrication (MQL) coolant process for different milling tool velocities. The shape and the size of the liquid film obtained by the calculation and the experiments were compared to improve understanding of the MQL cooling process. Overall, good agreement was observed between the numerical and the experimental measurements of liquid film size from an estimated numerical film thickness border. This study provided greater understanding of oil mist behavior. The impingement analyses predicted better lubrication when highly oriented channels and high inlet pressure were used, especially in High Speed Machining.

In the article the state of knowledge regarding the functions and supply methods of the cooling liquid into the grinding zone were presented. The new system for centrifugal supply of oil mist was described. The results of experimental investigations conducted into the internal cylindrical grinding process were given. The life of the wheel, machined surface roughness, grinding power and temperature in the machining zone were analyzed. Experimental results showed that compared to flood cooling, this new system provides double the lifespan of the wheel, significantly reducing the volume of wheel wear and enabling the slightly reduced roughness of machined surface and grinding power. Using a new coolant supply method caused an increase in the workpiece temperature, compared to the flood cooling.

Since the late 1960s, oil mist has excelled as an unusually simple and highly dependable lube application method. This article provides a relevant experience update on closed oil mist systems, summarizing the primary advantages of oil mist, discusses ‘old-style open’ and ‘new style closed’ oil mist applications and asks what, if anything, can shut down an oil mist system.

The growing cities, sharp increasing traffic, trajectory growth, rapid economic development and industrialization, and higher levels of energy consumption has resulted an increase of pollution load in the environment. It is also accepted that automobiles have emerged as a critical source of air pollution in the developing world. Realizing the gravity of the problem, steps are being taken to introduce better technologies, better fuel quality, shift to environment friendly fuels, and mass transit system for the control of environmental pollution in urban areas. Electronic diesel control, use of electronic FIE with increase in injection pressures and flexibility in injection control has changed the image of diesel engine. Engine optimization will lead to the better power with the better fuel economy which accomplish the urban living standard and care of the environment. Conventional fuel injection system was unable to fulfilment of this requirement, so it is necessity to modify fuel injection system along with vehicle after exhaust after treatment devices. Performance and Emission was optimized by using ETAS-INCA software. For the subject Bs-III engine, capacity is increased 50cc and certain modifications done. After proper optimization, with EGR ON the power value increased by 8.776% and torque value increased by 16.667% with respect to previous BS-III engine. Since the introduction of the new auxiliary system shows the gradual effect on the engine. According to the BS-IV norms the taper exhaust re-circulated by Oil Mist Separator (OMS) and to increase the performance the implementation of EGR Cooler is done. Also the BS-IV norms are achieved successfully in chassis dynamometer.

The aim was to study exposure to airborne contaminants in oil drillers during ordinary work. Personal samples were collected among 65 drill floor workers on four stationary and six moveable rigs in the Norwegian offshore sector. Air concentrations of drilling mud were determined based on measurements of the non-volatile mud components Ca and Fe. The median air concentration of mud was 140 μg m(-3). Median air concentrations of oil mist (180 μg m(-3)), oil vapour (14 mg m(-3)) and organic carbon (46 μg m(-3)) were also measured. All contaminants were detected in all work areas (drill floor, shaker area, mud pits, pump room, other areas). The highest air concentrations were measured in the shaker area, but the differences in air concentrations between working areas were moderate. Oil mist and oil vapour concentrations were statistically higher on moveable rigs than on stationary rigs, but after adjusting for differences in mud temperature the differences between rig types were no longer of statistical significance. Statistically significant positive associations were found between mud temperature and the concentrations of oil mist (Spearman's R = 0.46) and oil vapour (0.39), and between viscosity of base oil and oil mist concentrations. Use of pressure washers was associated with higher air concentrations of mud. A series of 18 parallel stationary samples showed a high and statistically significant association between concentrations of organic carbon and oil mist (r = 0.98). This study shows that workers are exposed to airborne non-volatilized mud components. Air concentrations of volatile mud components like oil mist and oil vapour were low, but were present in all the studied working areas.

The “wet pressure drop” of oil mist filters (i.e. the increase in differential pressure of the air flow due to loading of the filter with liquid) is presented as a function of two mechanisms by which coalesced oil is transported through the filter. These mechanisms operate in separate regions of the filter and make separate (and separately measurable) contributions to the overall wet pressure drop. This new concept, which was first formulated qualitatively in a phenomenological model by Kampa et al. (2014) , leads to semi-quantitative predictions regarding the dependence of pressure drop Δ p and saturation S on filter operating conditions, filter properties and liquid properties. These predictions are first formulated and then validated for a range of wettable and non-wettable filter media in combination with 4 mineral oils of different viscosity. The key findings, summarized below, are consistent with the model and apply to both wettable and non-wettable media. Oil transport across media interfaces (i.e. transitions between regions of different porosity and/or wettability) was associated with a relatively sharp increase in pressure drop ∆ p and oil saturation S over a very thin layer of the filter (a “∆ p jump”). The magnitude of this ∆ p jump was determined by the media properties. It correlated well with the respective static break-through pressures for oil or air, but did not depend on the oil viscosity and loading rate of the filter (at constant air velocity). Oil transport through channel regions of the filter (i.e. the regions connecting interfaces) was associated with a linear increase in ∆ p with channel length and liquid throughput. The corresponding saturation level S was relatively flat throughout the channel region and lower than at an interface. (Both quantities are media dependent, of course.) An increase in oil viscosity μ (at constant oil throughput) led to different responses depending on filter wettability.

Air pollution is an addition of harmful substances in the atmosphere, which results in environmental damage. The industrial development and reduction in forests which are two main root cause of air pollution has increased the death rates people dying from diseases like breathing problem and lung cancer. So, to fight against this serious threat to mankind, we decided to standby this society and we made our mind to do something to detect the amount of impurities in the air and considerably reduce the amount of impurity present in the air. In the project, we are detecting impurities using gas sensor. Impure air is input to the gas sensor. The sensor is connected to the Arduino which consist of code which will help us in detecting the amount of impurities in the air. After taking the inputs regarding the amount of impurities from the doctor we have set a limit up to which extent impurities are not harmful. If the limit exceeds then a buzzer sounds along with LCD display which gives us the information that it's time to switch ON the filtering device. After that filtering device gets turned ON and air gets purified. Coming to applications it can be used in the place where there is a need of oil mist collectors, dust collectors, UV air purifiers etc.

The present project focuses on the effects of occupational exposure to oil mists on a panel of exposure and effect biomarkers in an epidemiological study. The assumption is that different health outcomes are caused by reactive particles causing oxidative stress leading to lung inflammation and ultimately cancer or asthma. Ninety workers from France and Switzerland (30 controls, 30 exposed to straight cutting oil and 30 to soluble cutting oil) will be followed over two days after a non-exposed period of at least two days. The exposure assessment is based on measurements of particles, metals, aldehydes, amines, the intrinsic oxidative potential of aerosols and the cutting oil. Furthermore, exposure biomarkers are measured in exhaled breath condensate (EBC)- metals, ions (nitrite, nitrate...) and urine –metals, metabolites of PAHs- . Finally, exposure determinants will be collected to guide future efforts in exposure prevention. Effect biomarkers of oxidative stress (malondialdehyde, 8-isoprostane, 8-hydroxy-2’-deoxyguanosine) in EBC and urine will be repeatedly measured as well as exhaled nitric oxide (FeNO), an inflammation marker. Genotoxic effects will be assessed using the buccal micronucleus cytome assay. Finally, the possible chronic effects of oil mist exposure on respiratory health will be explored by standard questionnaires. This integrative project will gain insights in the exposure determinants that drive the physiopathological effects, thus allowing an efficient prevention strategy to be developed.

Aluminium workers are exposed to a complex mixture of airborne chemicals. Workers in different stages of aluminium manufacturing are exposed to different mixtures of chemicals. At twelve US aluminium facilities, we used information from an industrial hygiene database containing 30 years of sampling results for 227 separate chemical agents to build job exposure matrices (JEMs). We selected chemicals that represented major exposures in the workplace (e.g., oil mist and fluorides) and those that have been associated with heart disease [e.g., polycyclic aromatic hydrocarbons (PAHs) and welding-related metals]. We used cluster analysis to empirically group the chemical agents and establish exposure profiles by job. For PAHs and welding-related metal exposures, we also built quantitative JEMs. There were 21 PAH chemical agents, including individual PAHs (e.g. benzo[a]pyrene) and groups of PAHs (e.g. coal tar pitch volatiles). For metals, there were 54 different chemical agents associated with welding tasks. The categorical JEMs have three categories of exposure: unmeasured, very low exposure, and moderate or higher exposure. The stage of the manufacturing process made a large impact on the distribution of exposures. While 62% of jobs in smelters involved PAH exposures, only 2% of jobs in fabrication facilities did. Conversely, oil mist exposure is more common in fabrication facilities, compared with smelters (24% and 7% of jobs exposed, respectively). We observed that the exposure profiles in smelters was very different to those observed in fabrication facilities or refineries. These chemical exposure JEMs will help clarify the role chemicals play in heart disease.

Figure 1 is showing the gravimetric measurement system Topas GMS 141. The system is used to measure the condensate and oil concentration (oil carryover) in the full blow by stream of combustion engines. The quantity of the fluid blow by fraction is measured by the determination of the mass of a filter paper. The oil emission is determined in a steady state condition of the engine.

Water intrusion into gearboxes or, for that matter, other general-purpose machines is not desirable. Such intrusion will almost always have serious negative effects on a machine's overall reliability. Oil mist application and the installation of suitable bearing housing protector seals have greatly reduced premature bearing failures and have, in some cases, extended oil change intervals by a full order of magnitude.

Since the late 1960s, oil mist has excelled as an unusually simple and highly dependable lube application method. Compared to traditional liquid oil sumps in pumps and often ill-defined or labor-intensive grease applications in electric motor drivers, plant-wide systems today are orders of magnitude more reliable and cost-effective. An estimated 150,000 process pumps and 27,000 electric motors are presently (in early 2016) served by over 3000 plant-wide oil mist systems. From five to as many as 70 pumps and/or drivers can be connected to a given plant-wide system. The technology is widely used in advanced oil refineries and petrochemical plants; we call them “best-of-class” facilities. When electric motors are included and the oil mist is captured after traveling through equipment bearings, oil mist technology is cost-justified and represents both least-risk and best available technology for lubricating process pumps sets on a plant-wide basis.

Oil-mist is often used for minimum quantity lubrication of mechanical tools. For the measurement of the oil flow, inside compressed air, we propose a simple optical sensor, realized by a led source and a photodiode. The scattering spectrum, due to the oil particles, provides information about oil percentage and flow speed. The system is described by simulations and experimentally verified. The implemented algorithm allows for real-time measurements, with a low-cost microcontroller. The sensor characterization demonstrates performances and reliability adequate for industrial applications.

As the miniaturization of integrated circuits has progressed, the penetration holes of bonding jigs have become smaller. However, micro drills have a tendency to break when drilling small holes with high aspect ratios. Moreover, to reduce the impact on the environment, there has been a recent trend towards the use of lead-free brass as jig materials, but these are very difficult to drill. In the present study, small holes are drilled in lead-free brass using a micro drill, and the effects of web thinning, the helix angle, and the nick geometry on chip evacuation are investigated. The results indicate that drills with a helix angle of 15° have the longest tool life. The formation of a nick on the cutting edge is found to help decrease the thrust force during deep drilling. A drill with a relatively shallow nick perpendicular to the cutting edge have excellent chip discharge performance, and its cutting force is stable. Nick treatment effectively decreases the thrust force at a deep drilling position.

Minimum quantity lubrication (MQL) or as it’s called semi dry cutting is a technique which spray a small value of lubricant flow rate to the cutting zone area. MQL has been used in many machining process with different cutting tools and workpiece materials due to its green environments and economically advantageous. MQL has become an attractive option to dry and flood cutting in terms of reduce the temperature in the cutting zone and reduce the cost of the product. However, in MQL seems to be machining limited by cutting temperature, because at high speed the effect of oil mist becomes evaporated. Therefore another alternative cooling approach was used with oil mist in this research. This research presents study the performance of nitrogen gas as a coolant and oil mist as lubricant in turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Using a gas as coolant with oil mist is a new solution for enhancing machinability. Turning experiments are carried out on CNC turning machine. The cutting insert grade is KC5010 (PVD-TiAlN wiper coated carbide). The experimental results were: 1) nitrogen gas with oil mist prolongs tool life compare with air with oil mist. 2) better product surface finish by using nitrogen gas with oil mist.

Conventional coolant/lubricants have some drawbacks such as high cost, pollution, and unsatisfactory product quality. New cooling approach by using gases to enhance machinability has been investigated. This study presents the finding of nitrogen gas and nitrogen-oil-mist as conditions when turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Turning experiments were carried out on CNC turning machine using rhomboid type wiper coated carbide cutting inserts. The result show that better product surface finish and longer tool life, as well as decrease cutting temperatures could be achieved by using nitrogen-oil-mist condition compared to nitrogen gas condition.

An integrated approach was developed to assess exposure and health-risk from polycyclic aromatic hydrocarbons (PAHs) contained in oil mists in a fastener manufacturing industry. One previously developed model and one new model were adopted for predicting oil mist exposure concentrations emitted from metal work fluid (MWF) and PAHs contained in MWF by using the fastener production rate (Pr) and cumulative fastener production rate (CPr) as predictors, respectively. By applying the annual Pr and CPr records to the above two models, long-term workplace PAH exposure concentrations were predicted. In addition, true exposure data was also collected from the field. The predicted and measured concentrations respectively served as the prior and likelihood distributions in the Bayesian decision analysis (BDA), and the resultant posterior distributions were used to determine the long-term exposure and health-risks posed on workers. Results show that long term exposures to PAHs would result in a 3.1%, 96.7%, and 73.4% chance of exceeding the PEL-TWA (0.2 mg/m3), action level (0.1 mg/m3), and acceptable health risk (10−3), respectively. In conclusion, preventive measures should be taken immediately to reduce workers’ PAH exposures.

The use of the Hammond system for the machining of deep holes on numerically controlled machine tools is considered, so as to improve the precision in machining holes of length up to 3 m (diameter up to 40 mm) by gun drills.

Based on the dangers of suspended oil mist microparticles from machining to the environment and health of worker. A theoretical analysis on the generation mechanism of cutting fluid oil mist and an experimental study on its influencing factors were carried out in this paper. The experiment was conducted in closed lathe with flood cutting fluid feed system. A droplet diameter measuring system was equipped in the dense region of oil mist, which enables to observe the droplet distribution in air and scan the morphology of a single droplet accurately through its confocal microscopy. Droplet distribution and diameter were calculated through computer. In the experiment, effects of influencing factors on the oil mist concentration and average droplet diameter were discussed by controlling the revolutions per minute (rpm) of the main axis and cutting fluid flow, respectively. Experimental results demonstrated a significant effect of rpm on the characteristics of cutting fluid oil mist. As the rpm increased, the average droplet diameter decreased, whereas the oil mist concentration increased. As the cutting fluid flow increased, both of average droplet diameter and oil mist concentration increased.

This paper discusses the utilization of the minimum quantity lubrication (MQL) method in end milling using a coated carbide tool for stainless steel and titanium alloy workpieces. The effects of MQL were mainly evaluated by tool flank temperature, cutting force, tool wear behavior, and surface roughness. In MQL cutting of stainless steel and titanium alloy at cutting speed v = 25 m/min, the tool flank temperature decreased by approximately 50 and 100 °C, respectively, in comparison with dry cutting. The effect of MQL on tool flank temperature was especially pronounced at low-cutting speeds. Conversely, the tool flank temperature in MQL cutting of titanium alloy was higher than that of dry cutting at v = 100 m/min or more. In high-speed cutting of titanium alloy, it was observed that several chips had adhered to the cutting edge of the rake face, which reached a high temperature due to the heat generated by cutting. In the cutting of titanium alloy, the tool flank temperature at both a higher feed rate and depth of cut was lower than that in high-speed cutting under conditions where the cutting efficiency was the same. Peeling of the coating film covering the tool in dry and air-blow cutting of stainless steel and titanium alloy was more pronounced than that in MQL cutting. The surface roughness was greatly improved by supplying an oil mist in low-speed cutting of stainless steel.

The evolution of pressure drop, drainage rate, saturation, and efficiency of combined philic, and phobic oil mist filters in real-time are examined. The experiments used four different filter configurations, with a combination of oleophobic and oleophilic fibrous filter media, and one oleophilic only reference. The effect of separating filter materials of differing wettability, with a mesh, was also explored. It was found that inclusion of a mesh between layers promoted increased drainage rates and resulted in a significantly lower pressure drop across the filter. The overall mass-based filtration efficiency was also slightly higher for the configurations containing the mesh. Conversely, re-entrainment of droplets from the rear face of the filter was only observed in filter configurations without the central mesh. Filters with oleophobic initial layers did not display a classical “depth filtration” pressure drop curve. The oleophobic media was found to possess lower steady-state saturation than oleophilic media. Additionally, the steady-state saturation of the oleophilic filter media, when placed at the rear of the filter, was lower when the central mesh was present. The saturation values were compared with recently published theory. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2976–2984, 2014

Experimental studies that simulate grinding of hardened alloyed steel cams have demonstrated that these workpieces can be machined with a minimum work surface heating by using highly porous cubic boron nitride wheels with the oil mist cooling or without cooling. It has been found out that for minimizing the thermodynamic stress level in the dry grinding mode it is advisable to preset machining conditions with maximum possible depth of cut and minimum workpiece rotational speed.

Oil separation is commonly needed in air conditioning and refrigeration systems to reduce the oil circulation rate and keep the oil inside the compressor. For compactness, the oil separation structure integrated into the compressor is more and more popular than traditional external oil separators. This paper presents the impinging separation mechanism, one of the basic mechanisms of droplet separation. As a representative of the impinging separator, wave-plates structures are studied by flow visualization and experimental measurement under realistic compressor discharge conditions. The video of oil mist flowing through the baffles and plates is captured by a high-speed camera and analyzed quantitatively. The effect of the oil flow condition and the effect of separator geometry design are investigated based on the experimental data. With the help of flow visualization, the flow details are analyzed.

The technology of electrostatic minimum quantity lubrication (EMQL) can not only enhance the depositing rate of lubricant droplets on the cutting area, but also increase their wetting and penetration to the contact interface, which thus improve droplet lubrication and cooling, as well as reduce concentration of the oil mist floating in the cutting environment. As a EMQL cutting system is developed, the effect of charging voltages on the diameter and distribution of lubricant droplets are investigated, and droplet wettability and deposition on the cutting interface are analyzed. The heat transfer capacity of EMQL in steady stage and its machining performance and oil-mist concentration after turning are comparatively studied. By use of tool wear analysis, the lubrication mechanism of EMQL in the cutting process is revealed. Results indicate that as lubricant charged, droplet diameter decrease and its distribution improve with an enhancement in the wettability and deposition. The cutting temperature, oil mist concentration, tool wear and workpiece surface roughness of EMQL are 14%, 8%, 37% and 28% lower than those of the traditional MQL, respectively. When EMQL is used, the improved wettability and reduced droplet diameter allow lubricant droplets to enter and cover the tool-workpiece interface more easily, which would help lubricate and cool the cutting interface, and thus achieve a better cutting performance.

The high-concentration pickling and the extreme emission and energy consumption of the precision saponification process before the cold finishing of the precision forgings of the constant speed drive shaft of the car. Oil mist emissions from the cold finishing process and relatively harsh working conditions. The purpose of this paper is to develop a new saponification process that saves energy and reduces emissions while ensuring product quality during production. Through a large number of tests, it shows that the saponification of precision forgings for the drive shaft can be completed by three steps including simple saponification liquid spraying, liquid extraction and hot air drying. Thus in this way, the saponification quality is the best, At the same time, it has greatly reduced emissions, while the instability of the saponification quality mainly relates to the control of saponification process.

In order to well lubricate the industrial machine and decrease the consumption of lubricating oil, it is necessary to develop a system to monitor and control the density of oil mist. This paper introduces such a system based on LPC2214 of ARM7. The system can monitor 10 parameters, give an alarm to the status of factors which affect the quality of the oil mist and store the relative information into high capacity SD card through I2C bus and SPI bus. All the status information can be shown on LCD so that the operator can realize the system in real-time. System supplies input interface which can set some parameters and display other information on LCD, including history status information of system.Keywords: LPC2214, Oil mist, SD card, LCD