Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

Tracing nitrate transport and environmental impact from intensive swine farming using delta nitrogen-15

Natural-abundance delta15N showed that nitrate generated from commercial land application of swine (Sus scrofa domesticus) waste within a North Carolina Coastal Plain catchment was being discharged to surface waters by ground water passing beneath the sprayfields and adjacent riparian buffers. This was significant because intensive swine farms in North Carolina are considered non-discharge operations, and riparian buffers with minimum widths of 7.6 m (25 ft) are the primary regulatory control on ground water export of nitrate from these operations. This study shows that such buffers are not always adequate to prevent discharge of concentrated nitrate in ground water from commercial swine farms in the Mid-Atlantic Coastal Plain, and that additional measures are required to ensure non-discharge conditions. The median delta15N-total N of liquids in site swine waste lagoons was +15.4 +/- 0.2% vs. atmospheric nitrogen. The median delta15N-NO3 values of shallow ground water beneath and adjacent to site sprayfields, a stream draining sprayfields, and waters up to 1.5 km downstream were + 15.3 +/- 0.2 to + 15.4 +/- 0.2%. Seasonal and spatial isotopic variations in lagoons and well waters were greatly homogenized during ground water transport and discharge to streams. Neither denitrification nor losses of ammonia during spraying significantly altered the bulk ground water delta15N signal being delivered to streams. The lagoons were sources of chloride and potassium enrichment, and shallow ground water showed strong correlation between nitrate N, potassium, and chloride. The 15N-enriched nitrate in ground water beneath swine waste sprayfields can thus be successfully traced during transport and discharge into nearby surface waters.     

Impact of mining activities on soils in a semi-arid environment: Sierra Almagrera district, SE Spain

Field and laboratory-column studies were undertaken in order to investigate soil contamination derived from past mining activity in the Sierra Almagrera (SA) district in southeast Spain. The tailings, soil and sediment samples that were collected showed high concentrations of Ag, As, Ba, Cu, Pb, Sb and Zn when analyzed. The mean concentrations of these elements in the tailings were 29.8, 285.4, 54000, 57.7, 2687.5, 179.0 and 2269.0 ppm, respectively. In the soil samples these decreased to 14.3, 96.9, 24700, 37.5, 1859.1, 168.5 and 815.7 ppm, respectively. Geochemical analyses demonstrated high levels of As, Pb and Zn which were above the intervention values set forth in the Andalusian Regulations for Contaminated Soils for As (>50 ppm), Pb (>500 ppm) and Zn (>2000 ppm). Column experiments and mineralogical studies suggest that the dissolution of sulfates and other secondary phases, accumulated in soils and waste-sites during the dry season, acts to control the mobility of metals. The elution curves obtained from column experiments showed a mobilization of Ba, Cu, Pb and Zn, while a low mobility was seen for Ag, As and Sb.     

Emergent conservation outcomes of shared risk perception in human-wildlife systems

Human perception of risks related to economic damages caused by nearby wildlife can be transmitted through social networks. Understanding how sharing risk information within a human community alters the spatial dynamics of human-wildlife interactions has important implications for the design and implementation of effective conservation actions. We developed an agent-based model that simulates farmer livelihood decisions and activities in an agricultural landscape shared with a population of a generic wildlife species (wildlife-human interactions in shared landscapes [WHISL]). In the model, based on risk perception and economic information, farmers decide how much labor to allocate to farming and whether and where to exclude wildlife from their farms (e.g., through fencing, trenches, or vegetation thinning). In scenarios where the risk perception of farmers was strongly influenced by other farmers, exclusion of wildlife was widespread, resulting in decreased quality of wildlife habitat and frequency of wildlife damages across the landscape. When economic losses from encounters with wildlife were high, perception of risk increased and led to highly synchronous behaviors by farmers in space and time. Interactions between wildlife and farmers sometimes led to a spillover effect of wildlife damage displaced from socially and spatially connected communities to less connected neighboring farms. The WHISL model is a useful conservation-planning tool because it provides a test bed for theories and predictions about human-wildlife dynamics across a range of different agricultural landscapes.     

Flammability of heat transfer fluid aerosols produced by electrospray measured by laser diffraction analysis

Accidental release of pressurized high flash point heat transfer fluids can result in fire and explosion hazard scenarios in the process industry. An experimental investigation on ignition of aerosols of a heat transfer fluid is carried out, and characterization of aerosol and its ignition process by non-intrusive laser diffraction technique is reported. Propagation speed of the aerosol combustion flame front as analyzed from the laser diffraction measurement agrees with high-speed visual camera observation. Flammability of the aerosol, which is based on the chances of the global flame appearance in the aerosol, is mainly controlled by aerosol droplet size and the droplet volume concentration.     

Growth of Dehalococcoides spp. and increased abundance of reductive dehalogenase genes in anaerobic PCB-contaminated sediment microcosms

Polychlorinated biphenyls (PCBs) contaminate 19% of US Superfund sites and represent a serious risk to human and environmental health. One promising strategy to remediate PCB-contaminated sediments utilizes organohalide-respiring bacteria (OHRB) that dechlorinate PCBs.

However, functional genes that act as biomarkers for PCB dechlorination processes (i.e., reductive dehalogenase genes) are poorly understood. Here, we developed anaerobic sediment microcosms that harbor an OHRB community dominated by the genus Dehalococcoides. During the 430-day microcosm incubation, Dehalococcoides 16S rRNA sequences increased two orders of magnitude to 10⁷ copies/g of sediment, and at the same time, PCB118 decreased by as much as 70%. In addition, the OHRB community dechlorinated a range of penta- and tetra-chlorinated PCB congeners including PCBs 66, 70?+?74?+?76, 95, 90?+?101, and PCB110 without exogenous electron donor. We quantified candidate reductive dehalogenase (RDase) genes over a 430-day incubation period and found rd14, a reductive dehalogenase that belongs to Dehalococcoides mccartyi strain CG5, was enriched to 10⁷ copies/g of sediment. At the same time, pcbA5 was enriched to only 10⁵ copies/g of sediment. A survey for additional RDase genes revealed sequences similar to strain CG5’s rd4 and rd8. In addition to demonstrating the PCB dechlorination potential of native microbial communities in contaminated freshwater sediments, our results suggest candidate functional genes with previously unexplored potential could serve as biomarkers of PCB dechlorination processes.