Metalworking fluids (MWFs) are widely used in cutting and machining processes, where they generate problematic aerosols and vapors. These are currently extracted using centralized ventilation systems, which require significant energy to supply and condition replacement air. As a result, recirculating air solutions are gaining importance. However, they have so far failed to effectively remove MWF vapors.
The IntAbs project aims to develop a decentralized extraction system that removes both particles and vapors without consumable materials, thus enabling partial clean-air recirculation. At the heart of the system is a novel condensation separator with intelligent control that optimizes both air recirculation and energy consumption based on the operating conditions.
The approach combines numerical flow simulations (for the design of the separator and pipework), the construction and operation of a test platform on real machine tools, and laboratory and field tests with different MWFs. In parallel, appropriate sensors and control algorithms for system regulation are being developed and validated.
The project results will be transferred into practice in close collaboration with industrial partners. The developed prototypes will be tested and optimized under real-world manufacturing conditions and prepared for commercial implementation. The main target group is small and medium-sized metalworking companies that can reduce operating costs and improve occupational safety and sustainability through energy-efficient and low-maintenance extraction systems.