Abstract
Downsizing energy consumption during the machining of metals is vital for sustainable manufacturing. As a prerequisite, energy consumption should be determined, through direct or indirect measurement. The manufacturing process of interest is the finish turning which has been explored to generate (near) net shapes, particularly for hardened steels. In this paper, we propose using measured cutting forces to calculate the electrical energy consumption during the finish turning process of metals where typically the depth of cut is lower than the cutting tool nose radius. In this approach, the resultant cutting force should be used for calculating the energy consumption, instead of only the main (tangential) cutting force as used in the conventional approach. A case study was carried out where a hardened stainless steel (AISI 420, hardness of 47–48 HRC) was turned using a coated carbide tool, with a nose radius of 0.8 mm, without cutting fluid, and at 0.4 mm depth of cut. The experimental design varied the cutting speed (100, 130, and 170 m/min) and feed (0.10, 0.125, and 0.16 mm) while other parameters were kept constant. The results indicate that the electrical energy consumption during the particular dry turning of hardened steel can be calculated using cutting force data as proposed. This generally means machining studies that measure cutting forces can also present energy consumption during the finish or hard turning of metals, without specifically measuring the power consumption of the machining process. For this particular dry turning of hardened stainless steel, cutting parameters optimization in terms of machining responses (i.e., low surface roughness, long tool life, low cutting force, and low energy consumption) was also determined to provide an insight on how energy consumption can be integrated with other machining responses towards sustainable machining process of metals.
Highlights
With sustainable manufacturing in mind, a product’s manufacture should minimize energy consumption and negative environmental impact [1]
We identified that many works on hard turning reported the effect of machining parameters to quantitative machining responses like cutting forces, tool life, surface roughness, and cutting temperatures
In this study, we propose the use of resultant cutting force to approximate the electrical energy consumption in the hard turning of steels
Summary
With sustainable manufacturing in mind, a product’s manufacture should minimize energy consumption and negative environmental impact [1]. They showed that the machining process’s energy consumption could be predicted using the empirical models within the set cutting parameters for the selected machine tools Their model can calculate the energy requirement for turning or milling processes to machine a product. We agree with the approach proposed in a previous study [6] that the total energy consumption (E) for the turning process is a summation of the energy consumption during setup (E1), when performing material removal (E2), for tool change (E3), to fabricate the cutting tool (with all its cutting edges) (E4) and in the manufacture of the workpiece material (E5). Based on both Equations (9) and (10), the total energy consumption is only distinguished in the calculation of energy during the actual cutting process (E2), which is categorized as the variable factor. I.e., E1, E3, and E4 are the same for both Equations (9) and (10) and are considered as constant factors in energy consumption calculation [6]
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
