Abstract
The object of research is the process of transportation of mechanical waste from the machine tool to the area of further processing using a modernized screw conveyor. One of the biggest problems in the transportation of mechanical waste remains the high cost of auxiliary processes, which form the final cost of the product. Since it is impossible to reduce the cost by excluding the stages of transportation and processing from the technological process, the energy component of the issue remains. Reducing energy costs at all stages of machining, transportation and processing is an important economic and environmental challenge.In this work, the energy consumption of the conveyor is determined during the transportation of the shavings obtained during the end turning of the gear rim of the wheel. Also, the work is devoted to the movement of sludge obtained by surface grinding of the cover of a cylindrical gearbox. The examined shavings and sludge are in different states: dry, wet and unprepared.The analysis of the existing effective equipment for cleaning and moving with the stages of cleaning and processing of cutting fluids, shavings and sludge, taking into account the energy intensity, is carried out. A comparative analysis of the energy consumption of the conveyor, taking into account the energy consumption for the preparation of the transported material – the drying process, is carried out. Recommendations are given regarding the cases of using a dryer for the preparation of shavings and sludge for the processes of moving to the processing, cleaning or disposal zones. The effective values of the energy consumption of the conveyor are determined on the basis of graphical dependencies, based on the conditions of a given productivity.It is shown that obtaining the effective energy consumption of the conveyor is achieved due to the combined accounting of the energy consumption of the conveyor and equipment for the preparation of chips and sludge. This saves 5–7 % in energy costs for an expected performance of 12.4 g/min. As a research result, it is concluded that the effective energy consumption of the conveyor is 70–90 W/min for a given productivity of 10–12 g/min when transporting wet sludge and shavings.
Highlights
IntroductionDuring machining, cutting fluids (coolants) and detergents are used. When machining parts by cutting, the coolant enters the cutting zone, must be clean and free from chips, sludge and other impurities that reduce the cooling and lubricating effect
During machining, cutting fluids and detergents are used
Chips and sludge is a component of the production cost, to reduce which it is necessary to use variable technologies. These technologies include a decrease in electricity consumption due to the refinement of processing processes – switching off/on with the stages of transportation drying of chips and sludge, because the process of drying the chips and separating the cutting fluid from the sludge consumes up to 40 % of the energy consumption of the processing process
Summary
During machining, cutting fluids (coolants) and detergents are used. When machining parts by cutting, the coolant enters the cutting zone, must be clean and free from chips, sludge and other impurities that reduce the cooling and lubricating effect. Chips and sludge is a component of the production cost, to reduce which it is necessary to use variable technologies These technologies include a decrease in electricity consumption due to the refinement of processing processes – switching off/on with the stages of transportation drying of chips and sludge, because the process of drying the chips and separating the cutting fluid from the sludge consumes up to 40 % of the energy consumption of the processing process. Works [3, 4] are devoted to alternative methods of transportation and regeneration of liquids, taking into account the economic feasibility of the project. Works [5, 6] are devoted to improving the methods of transportation, processing and degreasing of wastewater In these studies, the energ y component of the issue remains unrevealed. The object of research is the process of transportation of mechanical waste from the machine tool to the zone of further processing using a modernized screw conveyor (Fig. 1) [11]
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