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Dry high speed machining has been proposed as a viable and cost-effective process in metal cutting industries. However, it produces fine and ultra-fine metallic particles, also referred to as dust, which can be harmful to the machine-tool operator. The risk associated with exposure to metallic particles increases as the particle size decreases. For machining processes, little data exist on the size and distribution of dust generated during the shaping of materials. In order to reduce or eliminate the generation of these particles, it is necessary to understand how and under which conditions they are formed, as well as to be able to make predictions. In this study, the effects exerted by tool geometry, material, and machining parameters on dust emission were studied experimentally in order to understand the mechanisms of dust generation and to develop a predictive model. The particle sizes studied include the PM2.5 (particles with aerodynamique diameter below 2.5 μm) and a distribution of nanoparticles varying in size from 10 nm to 10 μm. Using dry machining and reducing the amount of dust generated should improve the air quality in machine shops in addition to helping protect the environment.

Effects of Speeds, Materials, and Tool Rake Angles on Metallic Particle Emission During Orthogonal Cutting