1. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:1 Environmentally Conscious Design & Manufacturing Class 9: Health & Environmental Issues Prof. S. M. Pandit

2. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:2 1 Health and Environmental Issues l Cutting fluids in manufacturing l EPA water quality monitoring l Analytical monitoring tools l Health hazards l Where does it fit?

3. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:3 2 Additives: Chlorine, Sulfur, Phosphorus, Biocides, Odorants Cutting Fluids in Machining

4. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:4 Claimed Benefits of Cutting Fluids Lubrication Heat transfer Chip flushing ______________________________________ Increased tool life Reduced thermal deformation Improved surface finish Reduced forces Corrosion protection of surface Workpiece cleaner

5. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:5 Cutting Fluid Liabilities - 1 Fluid disposal due to contaminant build-up Fluid performance is time dependent Maintenance, disposal, handling, protection, and acquisition expensive Hazardous chemical constituents Source of occupational airway disease

6. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:6 Cutting Fluid Liabilities - 2 Source of contact dermatitis Excessive BOD, FOG, Nitrogen, Phosphates Expensive pre-treatment prior to disposal (wastewater currently sent to POTW - changes to permissible level of contamination being considered - may require additional expensive pretreatment)

7. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:7 Cutting Fluid Types (Straight Oils / Soluble Oils) Straight oils - Non-emulsifiable. Base oil, and often fats, veg. oil, & esters. May include extreme pressure additives such as Chlorine, Sulphur, Phosphorus. Soluble oils - Form emulsion when mixed with water. Typical concentrations of 3-10% - least expensive. Synthetic fluids - Formed from alkaline inorganic & organic comp. + corrosion inhibitors. Diluted form. Semisynthetic fluids - Combo. of synthetic & sol. oil.

8. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:8 Straight Oil EP Additives Some suggest that EP additives react with work material - form a barrier film that provides lubrication

9. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:9 Straight Oils: Pros and Cons Pros Cons Good lubrication Expensive - hard materials Rancidity & degradation Flammable resistant Good rust protection Smoke prone Low maintenance Health hazard Lack of cooling Viscosity low

10. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:10 Straight Oils vs. Water Solubles Straight Oils Water Solubles Degradation resistant High thermal conductivity Good lubrication Good cooling ability Easier to recycle More economical Good surface wettability Better operator acceptance Good rust protection No fire hazard Less oil misting

11. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:11 Cutting Fluids in Machining (reducing waste) Waste Reduction and Recycling Methods - Use water-soluble metal working fluids. - Use de-mineralized water make-up - Perform regularly scheduled sump and machine cleaning.

12. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:12 Arsenic Asbestos Barium Chromium Cyanide Mercury Nickel Nitrate Selenium Lead Copper Inorganics pHAlkalinity Testing water Question: What is happening to groundwater, lakes and rivers? EPA Water Quality Monitoring -1 (see epa.gov for complete list)

13. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:13 Benzene Carbon Tetra Chloride Chloroethylene Styrene Toluene Trichloromethanes Organics EPA Water Quality Monitoring - 2

14. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:14 Analytical Monitoring Tools Atomic Absorption

15. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:15 Mass Spectrometry

16. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:16 Mass Spec

17. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:17

18. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:18

19. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:19

20. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:20 ManufacturingLiquid wastes (cutting fluids)Testing of effluentsSource reductionWaste treatmentRecycle / Reuse Where Does It Fit?

21. Environmentally Conscious Design & Manufacturing (ME592) Date: March 24, 2000 Slide:21 Homework #3 The following problems are out of the textbook “Industrial Ecology” 1. Problem 8.1 2. Problem 8.2 3. Problem 9.3 Hint: A simple and reasonable technique is to sum the row entries and column entries. An overall rating is given by adding row totals(or the equivalent, column totals) so that the entire matrix is summed. Answer: Design 2 is better than design 1 because design 2 has higher overall score (48 to 43), and the product use rating, and many products have their greatest impact during the in-use stage.