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Computer Numerical Control (CNC) machining is a process where computer-aided design (CAD) and computer-aided manufacturing (CAM) programs are utilized to control the steps and functions of machine tool centers. CNC dust and mist collector equipment provides many manufacturing advantages, including improvement of component quality and work center efficiency. CNC-based mist and dust collectors are applied in various industries and processes.
Key benefits gained from using CNC dust and mist collectors include:
- Protecting the health of your employees
- Reduced exhaust air make-up requirements by up to 80% through recirculated conditioned air
- Extended machine life
- Reduced operational costs through reclamation of lubricants
- Improved part/product quality
- Reduced housekeeping costs
- Compliance with even the strictest federal, state, and local environmental standards
Contaminant Characteristics
Contaminants from CNC machining processes fall into three broad categories:
Metalworking Mist and Smoke: When coolants and lubricants are applied to machining processes, the generated force and heat create mist and smoke. The type of contaminant depends on what coolants are being used and the machining parameters. Water-soluble coolants produce a mist with larger droplet sizes, whereas straight oils produce more of a smoke that can be submicron in size. Higher-speed machines or processes that generate a large amount of heat will have higher concentrations of contaminants.
Dry Machining Dust: Dry machining will produce contaminants from the material being machined and the process heat. The contaminant will generally be a mix of larger particles from the displaced material and finer dust particles from the machining process. The material's properties, type of machining process, cutting rate, and the hours of operation affect the contaminant generation rates and contaminant size.
Plastic Fumes: When plastic materials are processed, a plasticizer contaminant is often emitted. This can happen during extrusion due to coatings or residuals left on a die or mold. They are generally submicronic smoke contaminants that are tacky or sticky. These emissions harm workers who can breathe in the hazardous particles during machine operation if the smoke is not adequately captured and controlled.
Recommended Approaches for CNC Machining Mist, Dust & Fume Control
Controlling CNC contaminants begins with a thorough review of the process. Keeping the volume under negative pressure with sufficient capture velocities in all open areas can effectively control the contaminants for machining centers. The airflow required is based on the contaminant type and the machining center's geometry.
When CNC machining is done without an enclosure, the following two methods are possible solutions for controlling the generated contaminant:
Source Capture: Capturing the mist, dust, and fume at the source is a practical approach for controlling CNC machining emissions. Source capture involves utilizing local or canopy hoods to capture the contaminant as it is generated. Capturing the contaminant at the source protects workers and prevents the contaminant from migrating throughout the factory. Source capture is the most effective means of capture and requires the least amount of energy and initial investment to accomplish.
Ambient Air Collection: When source capture is not possible, filtering ambient air can be utilized to control the fume concentrations in the facility to a more acceptable level. Ambient systems will help remove the ambient haze caused by airborne pollutants, but these systems will not protect the worker’s breathing zone.