Understanding the Formation of Nano and Micro Particles During Metal Cutting

Respiratory diseases caused by the inhalation of metallic particles become a serious problem. In previous research we presented experimental studies on the effects of cutting speeds, workpiece material and tool geometry on dust emission during dry machining. To limit dust emission, we must understand under, which conditions it is formed and be able to predict it. In this study, the origin and the mechanisms of particle emission are identified. The explanation of the origin of the particle emissions is based on phenomenological aspects: Energy approach combined with the friction and the plastic deformation of the workpiece material. The chip morphology is investigated to assess its effect on particle emission. The materials tested are 6061-T6 aluminum alloy, AISI 1018, AISI 4140 steels and grey cast iron during an orthogonal turning process.