Development of a Novel Metalworking Fluid Engineered for Use With Microfiltration Recycling

[+] Author and Article Information
J. E. Wentz, R. E. DeVor

Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801

S. G. Kapoor

Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801sgkapoor@uiuc.edu

N. Rajagopalan

Illinois Department of Natural Resources, Illinois Waste Management and Research Center, University of Illinois at Urbana-Champaign, Champaign, IL 61820

J. Tribol 129(1), 135-142 (Jun 27, 2006) (8 pages) doi:10.1115/1.2401207 History: Received March 15, 2006; Revised June 27, 2006

Membrane microfiltration is a promising technology that has been shown to extend metalworking fluid (MWF) life by eliminating contaminants while allowing the fluid to stay in use. However, the efficacy of this technology is compromised by the clogging of the filter pores in a process known as membrane fouling. In this paper the fouling issue is addressed by the development of a semi-synthetic MWF specifically designed to not foul microfiltration membranes. The composition of the designed MWF is discussed and compared with a commercial MWF. Cross-flow microfiltration fouling tests were carried out in low-pressure, high-velocity conditions on ceramic α-alumina membranes. Several common MWF components are shown not to be factors of membrane fouling on these membranes. The flux of the designed fluid was found to reach an immediate steady state at about twice the value of the steady-state flux of the tested commercial fluid. Scanning electron microscope imaging was used to further evaluate membrane fouling by each fluid. The machining capabilities of the designed fluid were examined in terms of cutting forces and machining temperature.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Membrane fouling by pore constriction (9)

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Figure 2

Membrane fouling by pore blocking

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Figure 3

Membrane fouling by cake formation (9)

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Figure 4

Cross-flow microfiltration of semi-synthetic MWF

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Figure 5

Microfiltration setup

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Figure 6

Commercial MWF flux decline

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Figure 7

Flux behavior of Fluid 5

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Figure 8

Flux behavior of Fluid 6

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Figure 9

SEM image of new membrane (20,000×magnification)

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Figure 10

SEM image of membrane used with commercial fluid (2000×magnification)

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Figure 11

SEM image of membrane used with Fluid 5 (20,000×magnification)

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Figure 12

SEM image of membrane used with Fluid 6 (20,000×magnification)



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