Size Characteristics of Machining Fluid Aerosols in an Industrial Metalworking Environment

Abstract In an industrial metalworking environment, workplace aerosols are produced continuously during normal operations as machining fluids flood the cutting or grinding tools at the machined surfaces. Since aqueous, synthetic fluids and soluble oils have replaced straight oils for the most part, the physical characteristics of the machining fluid aerosols should be determined to facilitate the assessment and control of potential health hazards in an industrial metalworking environment. The size distributions and mass concentrations of machining fluid aerosols in an automotive transmission manufacturing plant were determined by cascade impactors, real-time aerosol monitors, and a new area respirable impactor. The aerosols sampled at six sampling sites within the plant were found to be polydispersed with large droplets greater than 8 μm in aerodynamic mass median diameter and fine particles in the 0.1–1 μm size range. The large aerosols were formed from the direct spraying of machining fluids or from emi...