Currently, the cutting oil supply device is not equipped to cool the cutting oil. Therefore, additional cooling device should be connected to cool the cutting oil. This has the disadvantage of increasing the size of the device and reducing its cooling capability. To overcome these shortcomings, cooling coils are applied to the outside of the cutting oil filtering device to develop a heat exchanger filter for simultaneous coolant filtering and cooling to improve the compactness of the cutting oil supply device and cooling capability of the cutting oil. For the development of heat exchanger filter, flow and heat transfer analysis were performed. Due to the small heat transfer area of 10 cooling coils, less heat exchange occurred. In the 20 cooling coils, the coolant cooling coils prevented smooth flow of the cooling oil in the heat exchanger filter. The cooling efficiency of the 15 cooling coils were best, and the cooling temperature decreased non-linearly as the supply flow rate of the cutting oil increased.

As the demand for high-speed and high-precision machining increases, the need for cooling and filtering of cutting oil is high. A new concept of coolant heat exchange filter is developed by installing cooling coil through which refrigerant(R410-a) passes through the coolant filtering device. For structural safety evaluation of the heat exchanger filter for cutting oil suppling device of machine tool, thermal stress and vibration analysis were performed using ANSYS program. The results of structural and thermal stress analyses have led to the conclusion that the cooling system has structural stability. From modal analysis, first natural frequency is 12.37 hz and deformation is 22.041 mm. Sixth natural frequency is 26.887 hz and deformation is 25.563 mm.

Cutting tools tend to wear gradually with progressing of machining process due to extremely high surface loads and temperature from the relative motions between tool and workpiece. Especially, the high cutting temperature is a dominant factor in the relation to tool life. High-pressure coolant has been reported as an effective method to prevent the severe wear from cutting temperature. This research investigates efficient supplying conditions of high-pressure coolant with the CFD results from a internal-flush drilling process. The flow rate of coolant is increased drastically up to three times under 70 bar compared to conventional way.

본 연구에서는 0.5 wt% 에멀젼형 절삭유 수용액에 평막형 분리막을 침지시키고 대칭 및 비대칭 사인파형 투과유속 연속운전(SFCO) 방식으로 실험하였다. 사용한 정밀여과막은 유효 막면적이 0.02 m2이고 공칭 세공크기가 0.15 μm이었다. 탁도 기준으로 에멀젼형 절삭유의 99% 이상이 제거되었으며 산기량이 증가할수록 TMP가 낮게 상승하였다. 비대칭형 SFCO 운전방식은 투과유속이 낮은 10∼15 L/m2·h 영역에서 대칭형 SFCO 운전방식보다 다소 유리하였다. 하지만, 투과유속이 높은 25∼30 L/m2·h에서는 대칭형 SFCO 운전이 매우 효과적임을 확인할 수 있었다.

본 연구에서는 침지형 정밀여과막(공칭공경 0.15㎛, CPVC)을 사용하여 에멀젼형 절삭유(MECOOL-7000, Megalube사) 수용액을 처리하였다. 막 오염을 효과적으로 감소시키기 위하여 대칭형 또는 비대칭형의 사인파형 투과유속 연속운전(Sinusoidal flux continuous operation; SFCO) 실험을 실시하였다. 분리막의 투과유속이 증가함에 따라서 막간차압이 증가하였으나, 대칭형 운전방식이 비대칭형 운전방식에 비하여 막간차압이 낮게 형성되어 막오염 제어에 효과적임을 확인할 수 있었다.

Copper alloy metal fiber was incorporated into the conventional water-soluble metal working fluids to increase the antimicrobial activity. Fluid treated by copper alloy metal fiber is shown that bacteria is disappeared whereas that untreated metal fiber is increased bacteria as increasing the life time. When the electrochemical potential of Cu/Zn ion is -268mV, radicals with molecular oxygen are easily made. Especially, hydroperoxide radical shows strong toxicity to the strains, leading to the conformational change of plasma membrane. As a result antimicrobial activity of copper alloy metal fiber in metal working fluid is superior to that of copper fiber.

This study is focused on the possibility of copper alloy metal fiber for an antimicrobial activity in the water soluble metal working fluids. Electrochemical potential of Cu/Zn ion is -268mV, and easily makes radicals with molecular oxygen. Especially, hydroperoxide radical shows strong toxicity to the strains. Plasma membrane causes conformational change when hydroperoxide radical binds to plasma membrane. Elution of copper ion from copper alloy metal fiber is detected in metal working fluid. As a result antimicrobial activity of copper alloy metal fiber in metal working fluid is superior to that of copper fiber.

To provide an aqueous rust inhibitor for metalworking lubricant having low toxicity and excellent rust resistance, we synthesized diester of malonic acid by three consecutive esterifications with over 98% of conversion. This substituted malonic diester could be used as an additive to mineral oil based metalworking lubricant. These metalworking lubricant compositions were showed excellent rust resistance and suitable for various metals and different metalworking processes including hot rolling and cold rolling of aluminum and aluminum alloys.

The objective of ECMS(Environmentally Conscious Manufacturing Systems) is to consider environmental effects through the entire product life cycle from product development stage to design, manufacturing, supplying, using and disposing stage. Recently, environment-oriented recycling, reusing and manufacturing technologies have been researched actively in every engineering fields. In the field of chemical engineering, HHS(Health Hazard Scores) which classifies and analyzes hazardous materials in production processes has been presented. Metal cutting processes also have a lot of harmful factors, and especially hazardous components in cutting fluids have been known to have a bad effect on workers and working area. However, research works such as HHS have been little accomplished in metal cutting processes. In this research, a environmentally conscious machining process is presented by classifying hazardous components in cutting fluids, by using LCA(Life Cycle Assessments) and HHS method, and by evaluating environmental effects from cutting fluids.

The mother machine makes the necessary shape by processing materials such as metal. The SCFs are applied to the processing surface when the mother machine processes the material, thereby improving the cutting conditions. SCFs contain high concentrations of organic components and nitrogen compounds, which can cause problems such as eutrophication and algae bloom. Therefore, proper treatment is required. Electrochemical treatment is expected to be an alternative to conventional processes, and to be useful in various wastewater treatments. Moreover, it is an efficient elimination technique for contaminants and has a simple equipment composition. In this study, the removal efficiency of the T-N contained in the waste SCF using electrochemical treatment is analyzed. The electrode was made of titanium and iridium, made into a perforated metal sheet to prevent an imbalance of the sample concentration in the reactor. Experiments were conducted to examine the effects of current density and the concentration of the supporting electrolyte (NaCl, Na2SO4) on removal efficiency. In the cases with 60 A/m2, 80 A/m2, and 100 A/m2 current densities, the removal efficiencies of the T-N contained in the waste SCF were 51.03%, 68.83%, and 79.58%. Comparing between the addition and non-addition of NaCl, the removal efficiency with the addition of NaCl (5 ~ 10 mM) was higher than for no addition at 60 min for all current densities. The addition of Na2SO4 increased the removal rate of the T-N, but it was less effective than NaCl addition.

1970년대 수출주도 고도성장을 위해 정부는 조선･철강･기계 등의 중화학공업을 선택적으로 집중육성 하였다. 그 결과 일반기계산업은 1970년 수출 8백만불에서 2015년 현재 218,262백만불로 약 27,000배 이상 성장하였다. 일반기계산업에 있어 금속가공 공정은 필수적이며, 금속가공 공정에서 필요로 하는 것이 공작기계(Mother machine)와 절삭유(Soluble Cutting Fluids, SCF)이다. 절삭조건 개선에 사용되는 절삭유는 첨가제, 사용용도 등에 따라 원액으로 사용하는 비수용성과 물로 희석해서 사용하는 수용성으로 나뉜다. 국내 절삭유 이용량의 60%이상이 수용성 절삭유로 비수용성 절삭유의 오일미스트(Oil-mist), 폐유처리과정에서 유독성 물질 발생 등의 문제로 수용성 절삭유 사용량이 점차 증가하였다. 또한 절삭 성능 향상을 위한 방부제, 윤활제, 방청제, 부식방지제, 세정제, 극압 첨가제 등 각종 화학물질 첨가로 인해, 노출될 경우 췌장, 피부, 담낭, 방광, 소화기계 등 인체의 여러 조직에 암을 유발할 수 있으며, 각종 호흡기계 질환과 피부질환을 초래하는 것으로 알려져 있다. 인체에 미치는 영향 외에도 수용성 절삭유에는 고농도의 유기성분과 질소화합물 등이 함유되어 있어 적절한 처리 없이 수계로 유출시 부영양화, 녹조현상 등과 같은 문제를 일으킬 수 있으며 산화반응에 의해 수계의 용존산소를 감소시키므로 그 처리의 중요성이 부각되고 있다. 본 연구에서는 실공정에서 발생한 폐수용성절삭유를 원시료로 하여 대표적인 불용성 전극인 Ti/IrO2 전극을 이용하여 전기화학적 처리를 진행하였으며 연구에 사용한 장치의 모식도를 Fig. 1에, 시료의 성상을 Table 1에 나타내었다.

우리나라 경제의 성장을 이끈 기계산업은 2015년 현재 생산액 100조원, 사업체수 9,526개사, 종사자수 31만 5천명, 부가가치 39조원으로써 제조업 중 생산액 5위, 사업체수 2위, 종사자수 3위, 부가가치 4위에 위치하고 있다. 이러한 기계산업에 있어 공작기계를 이용해 금속을 원하는 모양으로 만드는 금속가공은 반드시 필요한 공정으로 금속가공 시 가공 장비의 수명 연장 및 가공물의 품질 향상을 위해 칩이 형성되는 영역에 적용되어 윤활 및 냉각작용을 하는 절삭유(Soluble Cutting Fluids, SCF)가 이용되고 있다. 절삭유는 수용성 및 비수용성으로 나뉘는데 비수용성 절삭유의 경우 윤활성은 우수하나 경제성 및 발연, 발화등의 문제점이 있으며, 수용성 절삭유는 윤활성은 비교적 떨어지나 냉각성과 경제성이 우수하다는 장점이 있다. 또한 절삭유는 기능 향상을 위해 PAH, 방부제, 파라핀계 염소, 아질산염 등 20~30개의 첨가제가 사용된다. 이는 중추신경계 장애, 이비인후 자극, 피부염 발생 등을 일으킬 위험성이 크다고 알려져 있으며, 고농도의 유기성분 및 질소화합물로 인해 수계에 유출시 부영양화, 녹조현상 등과 같은 문제를 일으킬 수 있다. 따라서 본 연구에서는 전기화학적 처리를 통해 반응시간에 따른 폐수용성 절삭유의 COD 및 T-N의 제거율 변화를 분석하였다. 전기화학적 처리의 중요 인자인 전극은 비교적 가격이 저렴하고 용출량이 낮은 것으로 알려져 있는 SUS316전극을 이용하였으며 자세한 실험 조건을 Table 1에, 연구에 사용한 장치의 모식도를 Fig. 1에 나타내었다.

Soluble Cutting Fluids (SCFs) have been used in metal machining processes to improve the quality of metal processing equipment and products. Although SCFs are useful and essential material, wasted soluble cutting fluids are harmful in hydroecological systems because of the high concentration of COD and nitrogen material. If discharged to hydroecological systems without specific treatment, they may cause eutrophication in rivers and lakes. Therefore, the removal efficiency of the COD contained in the SCFs is investigated in this study using electrochemical treatment with an insoluble electrode. The electrode was made of titanium with iridium plating, made from a perforated metal sheet to agitate the sample in the reactor. Cathode and anode electrodes were inserted into acrylic reactor alternately and the reaction time was one hour. The experimental results were as follows: First, for 60 A/m2, 80 A/m2, and 100 A/m2 current densities, the COD removal efficiencies were 42.0%, 63.9%, and 78.4%, respectively.

Soluble cutting fluids (SCFs) have been used in metal machining processes to improve the quality of metal processing equipment and products in modern society. Because the characteristics among metal machining processes differ, various types of cutting fluids are manufactured to enhance the cutting efficiency of different metals. Although SCFs are useful and essential materials, particular treatment is required attributable to the high concentration of nitrogen materials and chemical oxygen demand (COD). In this study, the removal efficiency of total nitrogen (T-N) contained in SCFs was analyzed using electrochemical treatment. The electrode was made of 316 stainless steel, which had been perforated to prevent an imbalanced sample concentration in the reactor. Cathodic and anodic electrodes were alternately inserted into an acrylic reactor. The removal efficiency of T-N in SCFs using 40 A/m2, 60 A/m2, and 80 A/m2 current density, was 48.2%, 61.5% and 69.3%, respectively. The removal efficiency of T-N in SCFs with the addition of 0, 5 mM, and 10 mM NaCl was 69.3%, 74.6%, 77.6%, respectively.

As industry continues to develop, the contents of various recalcitrant substances that are not removed by conventional wastewater treatment have increased in modern society. The metal working fluids (MWFs) used in the metal working process contain chemical substances, such as mineral oils, anticorrosive agents, extreme-pressure additives, and stabilizers, as well as high concentrations of organics and ammonia-nitrogen. Accordingly, MWFs are required to develop advanced treatments to conserve hydro-ecological resources. This study investigated the removal efficiency of ammonia nitrogen from MWFs according to operating time, applied voltage, and NaCl concentration using a Ti/IrO2 electrode in a batch-type reactor. The experimental results showed that ammonia-nitrogen removal efficiencies without NaCl were 89% and 92% when voltage was adjusted to 15 and 20 V for 60 min and removal efficiency was 90% at 25 V for 40 min. Removal efficiencies of 10 mM NaCl were 4% and 2% greater than those of not adding NaCl at 15 V for 50 min and 20 V for 30 min.

1900년대 초부터 금속 가공 장비의 수명 연장 및 가공물의 품질 향상을 위해 금속 가공 공정에 절삭유가 이용되어 왔다. 금속 가공 특성에 따라 절삭효율 향상을 위해 각종 첨가제를 포함시켜 여러 종류의 절삭유가 제조되고 있으며, 일반적으로 수용성과 비수용성으로 분류된다. 비수용성 절삭유의 경우, 폐유처리과정에서 유독성 물질 발생, 발연･발화 등의 문제로 수용성 절삭유의 사용이 점차 증가해 왔으며, 국내에서 이용되는 절삭유의 60% 이상이 수용성 절삭유이다. 사용된 수용성 절삭유는 비수용성 절삭유와 같이 소각처리 하기에는 비용이 크며, 수계로 유출시 COD 약 30,000~100,000ppm의 고농도 유기성분에 의해 인근 수계를 오염시킬 수 있으므로 각별한 처리가 필요하다. 따라서 본 연구에서는 Ti-IrO2전극을 이용하여 NaCl 첨가, 인가전압 변화를 통해 수용성 절삭유 내 오염물질의 전기화학적 처리에 미치는 영향을 검토하고, 수용성 절삭유의 전기화학적 처리에 대한 기초자료를 제공하고자 한다. 시료는 U사의 W1-1종 수용성 절삭유를 이용하였으며 증류수와 혼합하여 5% 농도의 인공 시료를 제조하였다. 시료의 특성은 Table 1, 실험 조건은 Table 2에 나타내었다.

2012년 현재, 국내 광공업 중 자동차 및 트레일러 제조업, 금속가공제품 제조업 등 금속가공을 필요로 하는 사업체는 전체 광공업 사업체 중 약 40%를 차지하고 있으며, 이와 같은 금속가공 과정에서 필요로 하는 것이 절삭유이다. 그러나 절삭유 내에는 50~80% 정도의 미네랄 오일 외에 amins, carboxylates, chlorine, glycols와 같은 부식방지제, 안정제, 습윤제, 극압 첨가제 등 20여종 이상의 화학성분이 다량 함유되어 있으며, 인체에 지속적으로 노출 시 호흡기 자극, 천식, 폐렴, 피부염, 모낭염 및 피부암 등을 일으키게 된다. 또한 고농도의 유기성분이 함유되어 있으며 유기성분 외에도 금속가공유 내 함유된 암모니아성 질소는 수생태계에 방류되면 부영양화 및 녹조현상과 같은 문제를 일으키며, 수중에서 산화반응을 하여 아질산성 질소와 질산성 질소로 변화되면서 수계의 용존산소를 감소시켜 수계 내 오염을 일으켜 각별한 처리가 필요하다. 따라서 본 연구에서는 수용성 절삭유의 효율적인 처리를 위해 용성전극인 알루미늄과 SUS316전극을 이용하여 전극간격, 전압, NaCl 농도변화를 통해 암모니아성 질소 제거 효율에 미치는 영향을 검토하여, 전극 특성과 각 인자에 따른 제거양상을 비교하였다. 본 연구에서 사용한 시료는 수용성 절삭유 W1-1종을 초순수와 함께 5%(V/V) 희석하여 사용하였으며 성상은 Table 1과 같다. 장치구성은 반응조, 전극, 전원공급장치, 전압안정기(AVR)로 진행하였으며, 장치모식도는 다음 Fig. 1에 나타내었다.

An electrochemical treatment has great efficiency for the removal of non-biodegradable material and it has high applicability in wastewater treatment due to its short operating time. The purpose of this study using an electrochemical process is to provide fundamental data on the cutting fluid treatment, which has difficulties in the treatment of nonbiodegradable material. The results are as follows. Experimental data in relation to applied voltage and concentration of NaCl are outlined. With no addition of NaCl, and an applied voltage of 5 V, 10 V, or 15 V for 60 mins, the removal rates of CODMn were 29.87%, 55.32%, and 67.27% for each voltage. The removal rates of CODCr were 39.51%, 70.73%, and 85.37%, respectively. The removal rates of CODMn and CODCr increased with increasing applied voltage. These experimental results showed that the removal rate of COD with varying concentrations of NaCl (0 mM, 5 mM, 10 mM) increased increasing NaCl concentration.