Analysis of Cutting Fluid Jet Impingement on a Flat Surface via Computational Fluid Dynamics

Cutting Fluid mist produced during machining operations is receiving increased attention by industry becasue of its adverse health effects. Thus, it is desired to obtain a fundamental understanding of the mechanisms that underlie mist formation. This knowledge can be used as a tool to design machining processes or systems that reduce the formation of cutting fluid mist and hence, the health hazard to which workers are exposed. Computational Fluid Dynamics is applied to investigate the problem, and a parametric study is performed to analyze the behavior of a cutting fluid when it impinges on a solid surface. A second-order, high-resolution Total Variation Diminishing (TVD) numerical scheme is incorporated to capture high velocity gradients. The results show that the TVD scheme can resolve free surface distortions and some fluid breakups. Validation is achieved by graphically comparing numerical results to a set of experimentally obtained images. The CFD analysis and experimental work indicate that the distance between the fluid nozzle and the work surface is the most critical variable in terms of mist formation.