Constituent analysis of aerosol generated from die sinking electrical discharge machining process

• Published in: Process safety and environmental protection Vol. 89; no. 2; pp. 141 - 150
• Main Authors: Sivapirakasam, S.P., Mathew, Jose, Surianarayanan, M.
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01-01-2011
• Subjects: Aerosol; Aerosols; Die sinking; Electric discharge machining; Electrical discharge machining; Hydrocarbons; Inductively coupled plasma; Metal particles; Morphology; Nanosized particles; Occupational exposure; Pulse duration; Taguchi methods; Taguchi methods; Occupational exposure; Aerosol; Electrical discharge machining; Nanosized particles
• ISSN: 0957-5820; 1744-3598
• DOI: 10.1016/j.psep.2010.10.003

▶ Emission of aerosol is an important occupational threat of die sinking EDM process. ▶ Peak current and the pulse duration are the most influential parameters in the generation of aerosol. ▶ 69% of aerosol generated from the EDM process constitutes of metallic particles. ▶ Aerosol emissions from the EDM process are attached with a complex mixture of about 20 hydrocarbons. ▶ The particle size of the aerosol was observed in the range of 25–29
nm.
This paper aims to study the influence of process parameters on the breathing zone concentration of the aerosol generated from the electrical discharge machining process using Taguchi methodology. Peak current, pulse duration, dielectric level above the spark location and flushing pressure were the process parameters considered in this work. Characterization of the components present in the aerosol and its morphology are also presented. The metallic particles present in the aerosol were analyzed using Inductively Coupled Plasma (ICP). Gas Chromatography coupled with Mass Spectrometry (GC–MS) was used to analyze the hydrocarbon components attached to the aerosol. Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) techniques were applied to study the morphology of aerosol. Analysis of the results showed that the peak current and the pulse duration are the most significant parameters on the breathing zone concentration of aerosol. Investigation using ICP revealed that the major portion of aerosol (about 69%) constitutes metallic particulates. GC–MS analysis of the aerosol samples indicated the presence of about 20 different hydrocarbons. Morphology studies showed that the particulates are of spherical shape with average sizes ranging from 20 to 29
nm. The control measures to minimize the risk of exposure have also been discussed in this paper.