Abstract
The sustainability of a manufacturing process can be measured by three main factors which impact both ecological and financial constraints. These factors are the energy required to achieve a specific job, the material utilized for the job, and the time taken to complete that job. These factors have to be quantified and analysed so that a proper manufacturing system can be designed to optimize process sustainability. For this purpose, a computer package, which utilizes life cycle inventory models has been presented for CNC (Computer Numerical Control) milling and turning processes. Based on utilization of resources and production stages, the job completion time for the turning and milling processes can be divided into process (i.e., machining), idle and basic times. As parameters are different for evaluating the process times, i.e., depth and width of cut in case of milling, initial and final diameters for turning, two different case studies are presented, one for each process. The effect of material selection on the sustainability factors has been studied for different processes. Our simulations show that highly dense and hard materials take more time in finishing the job due to low cutting speed and feed rates as compared to soft materials. In addition, face milling takes longer and consumes more power as compared to peripheral milling due to more retraction time caused by over travel distance and lower vertical transverse speeds than the horizontal transverse speed used in a peripheral retraction process.
Highlights
The system design for sustainable manufacturing is achieved by considering both ecological and financial constraints
The input of the presented work is a number of parameters, i.e., cutter-diameter, cutting-speed, feed rate, number of teeth, depth and width-of-cut, initial-final diameters and length of cut, rapid transverse speeds, some properties of material of workpiece, coolant, axis and spindle powers, load–unload-clean times, offset-approach distance etc. and output is times, power, energy at different phases of the machine process, along with chip mass which is the wastage material removed after finishing the job
The input of the presented work is a number of parameters, i.e., cutter-diameter, cutting-speed, feed rate, number of teeth, depth and width-of-cut, initial-final diameters and length of cut, rapid transverse speeds, some properties of material of workpiece, coolant, axis and spindle powers, load–unload-clean times, offset-approach distance etc. and output is times, power, energy at different phases of the machine process, along with chip mass which is the wastage material removed after finishing the job part
Summary
The system design for sustainable manufacturing is achieved by considering both ecological and financial constraints. Diaz et al [8] studied the procedures for exemplifying and minimizing the consumption of electrical energy of CNC milling tools They measured the power demands and specific energy variables of a micro-machining tools in which they use low carbon steel for cutting under different material removing rates. Guo et al [16] proposed two step methods in calculating the ideal cutting factors for finishing–turning processes in order to minimize the total energy consumption by achieving a quantified surface roughness They derived an energy and surface roughness model for a particular defined machine tool taken in the study. AA ccoommppaarriissoonn iiss ggrraapphhiiccaallllyy pprroovviiddeedd hheerree ffoorr ffaaccee aanndd ppeerriipphheerraall mmiilllliinngg ooff tthhee ssaammee mmaatteerriiaall iinn tteerrmmssooffttiimmee,,eenneerrggyy,,ppoowweerraannddwwaasstataggee.
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