1、Mist Control Considerations for the Design, Installation and Use of Machine Tools Using Metalworking Fluids -A amn American National Standards Institufe Il West 42nd Street New York, New York 10036 ANSI B11 TR 2-1 997 ANSI Technical Report for Machine Tools - Mist Control Considerations for the Desi
2、gn, Installation and Use of Machine Tools Using Metalworking Fluids Secretariat AMT -The Association For Manufacturing Technology Approved April 13, 1997 American National Standards institute, inc. Published by I AMT - The Association For Manufacturing Technology 7901 Westpark Drive, McLean, Virgini
3、a 22102 Copyright O 1997 by AMT - The Association For ManufacturingTechnology All rights reserved. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior wriien permission of the publisher. Printed in the United States of America CONT
4、ENTS 1 2 3 4 5 6 7 8 9 10 A B C D E . FOREWORD . III SCOPE . 1 REFERENCED AND RELATED PUBLICATIONS 2 DEFINITIONS . 2 HAZARD ANALYSIS AND RISK ASSESSMENT 4 CONSIDERATIONS FOR THE DESIGN OF METALWORKING FLUID DELIVERY SYSTEMS . 7 CONSIDERATIONS FOR THE DESIGN OF MACHINE TOOLS 14 CONSIDERATIONS FOR THE
5、 DESIGN OF MACHINE ENCLOSURES FOR THE CONTROL OF AIRBORNE CONTAMINANTS 17 CONSIDERATIONS FOR THE DESIGN OF EXHAUST DUCTWORK FROM MACHINE TOOL ENCLOSURES . 25 CONSIDERATIONS FOR THE DESIGN OF MIST COLLECTORS 27 GUIDELINES FOR TESTING COLLECTION SYSTEMS . 32 ANNEXES: RESPONSIBILITY CHECK LIST 34 MACHI
6、NE SHED PLATE ILLUSTRATION . 37 MACHINE SHED PLATE ILLUSTRATION . 38 TYPICAL DRAIN TRAP 39 VENTILATION MANUAL 40 II Foreword The Machine Tool Safety Standards Committee (BI 1) of the American National Standards Institute formed a cubcommittee consisting of professionals that are involved in manufact
7、uring, higher education, industrial hygiene, safety, and design to develop guidelines for the control of airborne contaminants associated with metalworking. The subcommittee operates under the auspices of AMT-The Association For Manufacturing Technology, located in McLean, Virginia. Publication of t
8、his ANSI Technical Report has been approved by the Accredited Standards Developer, AMT-The Association For Manufacturing Technology. This document is registered as a Technical Report series of publications according to the Procedures for the Registration of ANSI Technical Reports. This document is n
9、ot an American National Standard and the material contained herein is not normative in nature. Comments on the content of this document are welcome and should be sent to AMT-The Association For Manufacturing Technology, 7901 Westpark Drive, McLean, VA, 221 02, Attention: Safety Department. There are
10、 several informative annexes at the end of this technical report which are used for clarification, illustration, and general information. iii The B11 Parent Voting Committee had the following members at the time it approved this technical report. Organization Represented Aerospace Industries Associa
11、tion of America, Inc. Alliance of American Insurers American Automobile Manufacturers Association American Boiler Manufacturers Association American Insurance Services Group American Institute of Steel Construction American Ladder Institute American Society of Safety Engineers AMT-The Association Fo
12、r Manufacturing Technology Can Manufacturers Institute Computer 8 Business Equipment Manufacturers Defense General Supply Center Forging Industry Association Graphic Gregory J. Mac, Chairman Daniel W. White, Secretary The working group developing the “Considerations for the Design of Metalworking Fl
13、uids Delivery System“ section had the following members: Gregory J. Mac, Chair Thomas Cherniak Bill Lucke Robert Oaks Clayton Tenniswood, PE William D. Watt Dent Williams The working group developing the “Considerations for the Design of Machine Tools section had the following members: Daniel McCart
14、hy, Chair Daniel E. Goodman Jim Linthicum Bill Lucke Gregory J. Mac Stephen L. Stevens Dent Williams The working group developing the “Considerations for the Design of Machine Enclosures and Exhaust Ductwork“ section had the following members: William Johnston, Chair Walt Diachuk Donald E. Gault Wil
15、liam G. Gerlach Daniel E. Goodman Gerry A. Lanham, PE Daniel W. White, PE The working group developing the “Considerations for the Design of Collectors“ section had the following members: Faith Salchert, Chair Rob Cardella Walt Diachuk Curt Engelstad William Gault Tim Grafe Dave Hands Gary M. Hutter
16、 Jim Kohl Bob Kraymer Ken Matuszak Gary Pashaian The working group developing the “Guidelines for Testing Collection Systems“ section had the following V members: William Gault, Chair Bill Cleary Mark Engel Dave Hands Hank Lick Faith Salchert vi ORGANIZATIONS REPRESENTED AIR FILTRATION CONCEPTS - SO
17、UTHFIELD, MI AMERICAN AIR FILTERS PRODUCTS - LOUISVILLE, KY AMERICAN FOUNDRYMENS SOCIETY - DES PLAINES, IL AMERICAN AIR FILTER - LIVONIA, MI CHRYSLER CORP. - HIGHLAND PARK, MI CINCINNATI MILACRON - CINCINNATI, OH DGSC-SS - MEMPHIS, TN DONALDSON - MINNEAPOLIS, MN DONALDSON - MINNEAPOLIS, MN DONALDSON
18、 - MINNEAPOLIS, MN DUSTVENT, INC. -ADDISON, IL EPPERT OIL CO. - DETROIT, MI FORD MOTOR COMPANY - DEARBORN, MI FORD MOTOR COMPANY - DEARBORN, MI FORD MOTOR COMPANY - DEARBORN, MI FORM CUT ENGINEERED FLUIDS, INC. - PONTIAC, MI GENERAL MOTORS CORP. - DETROIT, MI GENERAL MOTORS CORP. - ROMULUS, MI GIDDI
19、NGS with a decrease in temperature vapors can condense. 3.37 m: Volatile Organic Compound. 3.38 Water Soluble Oil: A water based metalworking fluid that is comprised of an emulsion of oil (or oil-like material) in water. It may or may not include Performance enhancing additives. 4 HAZARD ANALYSIS 4.
20、1 An assessment of the Dotential risks from the materials and processes used will be made 4 ANSI BI1 TR 2-1997 Mist Control to determine their risks to worker occupational health. This assessment will cover potential worker exposure from mists, dusts, vapors, fumes, gases, and microbiological activi
21、ty of metalworking fluids. The assessment should be done as part of system development, but will be the ultimate responsibility of the machinery user. 4.2 The level of risk depends not only on the hazardous properties of the materials and process used, but by the manner of use and the precautions ta
22、ken. Health effects of the materials and process may include: 4.2.1 Short term effects such as upper and lower respiratory irritation. 4.2.2 Dermatological effects. 4.2.3 Sensitization. 4.2.4 Potential long term health effects. 4.3 Routes of Entry in the Body of a Worker Include: 4.3.1 Inhalation. 4
23、.3.2 Ingestion. 4.3.3 Contact with skin, eyes, and mucous membranes. 4.3.4 Penetration through intact skin. 4.4 General Issues Associated With Worker Exposure To Metalworking Fluids 4.4.1 Methods of evaluating fluid condition. 4.4.2 Addition of additives and biocides. 4.4.3 Composition of fluids int
24、roduced into metalworking fluid systems and composition at disposal. 4.4.4 Use of reclaimed fluids and their associated hazards. 4.4.5 Safe and effective fluid disposal. 4.4.6 Contamination of metalworking fluids from machine degradation (.e., hydraulic fluid, paint, greases, etc.). 4.4.7 Contaminat
25、ion associated with tool composition. 4.4.8 Relative hazards of synthetic, semi-synthetic, soluble, and straight oil metalworking fluids. 4.4.9 Potential for presence of chemical or biological hazardous substances. 4.4.1 O Vapor exposure from some metalworking fluid formulations. 5 ANSI B11 TR 2-199
26、7 Mist Control 4.5 Airborne Contaminants The production of metalworking fluid aerosols (coolant mist, oil mist, oil vapor, and oil smoke) cannot be isolated to a single factor, and is a combination of several factors including: 4.5.1 Metalworking fluid pressure. 4.5.2 Compressed Air Pressure. 4.5.3
27、Lack of effective splash guarding. 4.5.4 Metalworking fluid type. 4.5.5 Metalworking fluid nozzle size, type and position. 4.5.6 Metalworking fluid temperature. 4.5.7 Exhaust ventilation and air supply design, volume, configuration, location and distribution. 4.5.8 Tool type and speed. 4.5.9 Velocit
28、y trench design and condition. 4.5.10 Use of chip drags. 4.5.1 1 Fixture and part configuration and shape. 4.5.12 Metalworking fluid condition. 4.5.1 3 Continuous vs. non-continuous application of metalworking fluid. 4.5.1 4 Air cleaner/collector design, appropriateness, and efficiency. 4.5.1 5 Gene
29、ral housekeeping around machining lines. 4.5.1 6 Metalworking fluid chemical composition. 4.5.17 Metalworking fluid management techniques. 4.5.1 8 Preventive maintenance. 4.5.19 System filtration. 4.5.20 System aeration. 4.5.21 Control of tramp oil and other contamination. 6 ANSI BI1 TR 2-1997 Mist
30、Control 5 CONSIDERATIONS FOR THE DESIGN OF METALWORKING FLUID DELIVERY SYSTEMS 5.1 Introduction The generation of airborne contaminants can be minimized through the proper design and operation of the metalworking fluid delivery system, and through the proper selection and maintenance of metalworking
31、 fluid. 5.2 Metalworking Fluid Application: 5.2.1 The following generalities can be applied to a given metalworking fluid application: 5.2.1.1 The higher the oil content in a metalworking fluid, the higher the concentration of mist that will be generated. 5.2.1.2 The higher the temperature of a meta
32、lworking fluid, the higher its evaporation rate. 5.2.1.3 The higher the discharge velocities of metalworking fluids through application nozzles, the higher the concentration of mist generated. 5.2.1.4 The higher the tramp oil contamination level in a water-based fluid system, the higher the concentr
33、ation of mist generated. 5.2.1.5 The more unstable the emulsion in a water soluble oil fluid, the higher the concentration of mist generated. 5.2.1.6 The higher the viscosity of a metalworking fluid, the higher the frictional losses in a system, and thus, the higher the temperature of the fluid. 5.2
34、.1.7 The higher the flow rate of metalworking fluid used, the higher the concentration of mist generated. 5.2.1.8 The more fluid surface exposed to atmosphere, the higher the evaporation rate. 5.2.2 From these generalities come the following directives for minimizing mist or vapor generation: 5.2.2.
35、1 5.2.2.2 5.2.2.3 5.2.2.4 5.2.2.5 5.2.2.6 5.2.2.7 Minimize fluid delivery pressures. Match fluid to application. Use low oil concentrations where possible. Minimize tramp oil contamination. Maintain control of metalworking fluid chemistry. Minimize the metalworking fluid flow rate. Cover fluid reser
36、voirs and return systems as much as possible. 7 ANSI BI1 TR 2-1997 Mist Control 5.2.2.8 Maintain a low metalworking fluid temperature. 5.3 Metalworking Fluid Selection 5.3.1 Straight oils: 5.3.1.1 Straight oils are not very effective at dissipating heat, and therefore will run at higher temperatures
37、 than water-based fluids. 5.3.1.2 Straight oils are generally more viscous than water-based fluids. The associated frictional losses in a system also act to raise the temperature of the fluid. 5.3.1.3 Straight oils generate mist readily, even at low velocities. 5.3.1.4 Straight oils evaporate at a m
38、uch lower rate than water-based fluids. 5.3.1.5 Straight oils are stable, and require minimal maintenance. 5.3.2 Water soluble oils: 5.3.2.1 Water soluble oils are very effective at dissipating heat. 5.3.2.2 Water soluble oils have viscosities close to that of water 5.3.2.3 Water soluble oils dont g
39、enerate mist readily at low velocities. 5.3.2.4 Water soluble oils evaporate at a faster rate than straight oils. This tends to humidify the air and to remove heat from the fluid. 5.3.2.5 Water soluble oils require maintenance of several chemical parameters in order to assure a stable emulsion. 5.3.
40、2.6 Water soluble oils are readily affected by tramp oils, affecting both fluid stability and misting capabilities. 5.3.3 Semi-synthetic fluids: 5.3.3.1 The characteristics of semi-synthetic fluids are similar to those of water soluble oils and synthetics. 5.3.3.2 The misting tendencies of semi-synt
41、hetic fluids fall between water-soluble oils and synthetic fluids. 8 ANSI BI1 TR 2-1997 Mist Control CHARACTERISTICS EVAPORATION METALWORKING FLUID CHARACTERISTICS CONTRIBUTING TO AIRBORNE CONTAMINANT GENERATION Ranking Key: l=low, 3=high MIST HEAT VISCOSITY MAINTENANCE GENERATION DISSIPATION INPUT
42、REQD. STRAIGHT OILS WATER SOLUBLE OILS SYNTHETIC FLUIDS SEM I-SY NTHETIC FLUIDS 1 3 1 3* 1 3 2 3 1 3 3 1 3 1 2 3 2 3 1 3 * Generally, straight oils are more viscous, however some applications (e.g., honing) utilize oils with viscosities approaching that of water. 5.3.4 Synthetic fluids: 5.3.4.1 The
43、characteristics of synthetic fluids are similar to those of water soluble oils. 5.3.4.2 Synthetic fluids generate slightly lower mist concentration than water soluble oils. 5.3.4.3 Synthetic fluids are less likely to be affected by tramp oils than water soluble oils. 5.4 METALWORKING FLUID DELIVERY
44、SYSTEM COMPONENTS 5.4.1 system. Pump: the device that takes fluid from a reservoir and transfers it to the delivery piping 5.4.2 Delivery piping system: the artery which takes fluid from the pump discharge, and delivers it to the machine distribution piping network. 5.4.3 Machine distribution piping
45、: a network which takes a single fluid stream and divides it as necessary to supply the fluid applicators. 5.4.4 Fluid application: nozzles at the termination points of the machine distribution piping which direct fluid towards the tool, workpiece, and/or swar generated. 5.4.5 Shedding: chuting, pla
46、tes and piping within a machine which directs used fluid and generated swarf into the return system or fluid reservoir. 5.4.6 Return from machine: above or below floor conveyance used to carry metalworking fluids and generated swarf into the fluid reservoir. This is not required when the reservoir i
47、s integral to the machine. 5.4.7 Fluid reservoir: a vessel which receives the metalworking fluid from the machine return, and from which the pumping equipment draws. It may be part of a clarification system which separates the swarf prior to repumping. Fluid clarification is an important part of flu
48、id maintenance. 9 ANSI BI 1 TR 2-1997 Mist Con tro I Fluid Reservoir Metalworking fluid flush. 6.2.1.7.2 High pressure (greater than 50 P.S.I.); Gun-drilling and coolant through tools. 6.3 Machine Features 6.3.1 Chip shedding 6.3.1.1 Maintain a shedding angle of 43“ from horizontal minimum in idle s
49、tations. (See Annex B) 6.3.1.2 Maintain a shedding angle as close to vertical as possible in work stations. 6.3.1.3 Maximizing shedding angles will generally reduce coolant flow required to clear chips. 6.3.2 Base Types 6.3.2.1 Continuous Weld - These bases have less chance of leaks and lower noise transmission but more supporting members are required. These supporting members may trap chips and require more metalworking fluid flow to clear chips. 6.3.2.2 Cast - These bases have fewer supporting members and thus fewer chip traps and fewer surfaces to create mist by impact. 6.3.2.3 Fewer
