The study is dedicated to the design of aspiration systems for machining equipment. The study presents an empirical-theoretical model of metal dust generated during cast iron milling. Based on the sieving analysis of 90 samples selected in the working areas of machines under various modes of cutting and cooling, two particle size distribution models have been compared, namely the Rosin — Rammler model and the lognormal model. It has been established that the gray cast iron dust is highly polydisperse. Although the lognormal model demonstrates a higher accuracy for the approximation of experimental data, the Rosin — Rammler model is recommended for practical use. Physical adequacy within the ultrafine range is considered. The model predicts the growth of the share of fractions PM1–PM10 harmful for human health, which complies with the brittle fracture mechanism of cast iron and the data of other studies. The results of the study allow for the correct presetting of particle size distribution during the CFD-DEM modeling, designing dust collection systems, and assessing occupational risks, considering the most harmful submicron particles. Parameterized models for three technological modes are provided, considering milling cooling in five measuring points.
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