Abstract
Enhancing energy efficiency is the key to realizing green manufacturing. One major area of interest in this regard is the improvement of energy efficiency of machine tools during the production of building materials. This project focuses on energy efficiency during the spiral milling of wood plastic composites. To this end, a response surface method was adopted to develop a model and establish the relationship between energy efficiency and milling conditions. Analysis of variance based on individual factors as well as two-factor interactions was performed to gauge their effects on energy efficiency. It was found that milling depth was positively correlated to power efficiency, while spiral angle and feed per tooth displayed non-monotonic behavior. An attempt was made to predict milling conditions that will yield the greatest material removal rate and power efficiency. For wood plastic composites subjected to up-milling, it was determined that a feed per tooth of 0.1 mm, milling depth of 1.5 mm, and spiral angle of 70° were ideal. Considering the potential improvements in energy efficiency and surface quality that these process parameters will bring, it is strongly recommended for use in the industrial machining of wood plastic composites.
Highlights
The manufacturing industry has advanced at a rapid pace and with it, high-performance manufacturing techniques h become critical to attain sustainable development [1], improve power [2] and processing efficiency [3], and increase machining quality [4]
It is not surprising that many research efforts over the years have investigated the optimization of cutting parameters during machining, such as cutting force, tool wear, power, and quality [6,7]
Dong et al [8] studied the effects of tool wear on cutting power and found that did cutting power increase with tool wear, but changes in the tool’s cutting power indicated wear conditions in real time
Summary
The manufacturing industry has advanced at a rapid pace and with it, high-performance manufacturing techniques h become critical to attain sustainable development [1], improve power [2] and processing efficiency [3], and increase machining quality [4]. The two main factors that influence machining tool energy consumption and product surface quality are cutting parameters and tool geometries [5]. It is not surprising that many research efforts over the years have investigated the optimization of cutting parameters during machining, such as cutting force, tool wear, power, and quality [6,7]. Cao et al [9] adopted an orthogonal design to optimize parameters and reduce energy consumption and surface roughness of milled glass magnesium boards. Zhu et al [11,12] adopted a response surface method (RSM) to minimize cutting force, reduce surface roughness, and maximize removed volume in the milling of a stone-plastic composite. Despite the differences in approach, these optimized cutting conditions have led to significant reductions in energy opctoinmsiuzmedptciounttiwnhgilceosnimdiutilotannsehouavsleyliemdptroovsiinggnisfiucrafancterqeduaulcittyio.
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