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Factory of Tomorrow

Development of a comprehensive procedure within the design of high-speed-cutting processes in consideration of environmental protection and occupational health aspects

In the metal working industry high-speed-cutting (HSC) in connection with minimal quantity cooling-lubrication promises a high potential for saving process materials. On the one hand costs of purchase and disposal of metal working fluids (MWF) decrease, on the other hand the reduction of dermal diseases and emissions of MWF-dusts are expected.

Short Description

Status

completed

Summary

In the metal working industry high-speed-cutting (HSC) in combination with minimal quantity cooling-lubrication promises a high potential for saving process materials. On the one hand costs of purchase and disposal of metal working fluids (MWF) decrease, on the other hand the reduction of dermal diseases and emissions of MWF-dusts are expected. The utilisation of these technologies is not spread widely, because reliable machining data are not available yet. Therefore the development of practicable procedure for process optimisation is useful. The milling process of an aluminium workpiece was optimised regarding environmental and occupational safety and health aspects. With the means of laboratory tests the consumption of MWF was decreased by substitution with an emulsion and strict minimisation of quantity. The emission of aerosol was measured with a low pressure impactor, which allows the classification of particle size in the range between 20 and one micrometer. The results of the laboratory tests and of the employee-interviews were discussed in workshops and an optimised "workplace of best practice" was defined. Organisational and ergonomic improvements were established additionally.

Overall the results of the implementation were positive, but the MWF-supply does not work satisfying by using such small quantities of emulsion. Therefore the need of research in minimal cooling lubrication systems with the use of emulsion is necessary.

Project Partners

Project manager

DI Dr. Ewald Wahlmüller
PROFACTOR Produktionsforschungs GmbH

Project and cooperation partners

  • Johann Hieslmayr
    Piesslinger GesmbH
  • Univ. Prof. Dipl.-Ing. Dr. Wilhelm Höflinger
    Institut für Verfahrenstechnik-, Brennstoff- und Umwelttechnik; TU-Wien

Contact Address

PROFACTOR Produktionsforschungs GmbH
Wehrgrabengasse 1-5, A 4400 Steyr