Characterization of fine particles from machining in automotive plants

Sampling of the full range of particle sizes was carried out on 16 processes in six different General Motors plants over a period of 2.5 years. This article deals with particle characterization from five of the processes that relate to machining, specifically, wet machining with water-based fluids from old and new technology processes, grinding with straight oils from old and new technology processes, and dry machining. The concentrations measured by different instruments were in reasonable agreement, although the light-scattering instrument generally produced higher values than filters. Of the processes studied, the old technology grinding using straight oils generated the highest particle concentrations. The new technology controls (enclosed, vented machines) were highly effective but more so for large particles than small particles. The particle size distribution was shifted to smaller particles with enclosed processes. Dry machining generated the largest particles of all processes studied.