Abstract
Edge-finishing of granites by grinding is a process frequently used in the granite processing industry to generate the final desired shape and edge quality of products. However, this process releases significant amounts of fine and ultrafine particles (FPs and UFPs) containing crystalline silica. When inhaled, this dust can cause silicosis disease and threaten the health and safety of workers. The purpose of this study is to optimize the process by decreasing the concentrations of dust generated while also maintaining the required surface finish. Experimental tests were planned and performed on granite samples using a full factorial design. Two cutting tool edge shapes were studied (chamfer and concave) using G150 and G600 grit size tools, at various spindle speeds (1500, 2500, 3500 rpm), feed rates (500, 1000, 1500 mm/min) and lubrication flow rates (20, 40, 60 mL/min). The findings show that the particle emissions as well as the surface finish depend on the tool shape, its grit size, and the machining and lubrication parameters used. Higher MQL flow rates led to better finished surface quality and lower concentrations of fine dust. Polishing with flood lubrication reduces the maximum number concentration of FPs corresponding to particles smaller than 1 µm diameter by about 85% as compared to dry polishing and produced the best surface finish. Polishing with lubrication in MQL mode at 60 mL/min led to the production of part with Ra-value comparable with that obtained in flood lubrication condition.