Abstract
As the manufacturing industry is facing increasingly serious environmental problems, because of which carbon tax policies are being implemented, choosing the optimum cutting parameters during the machining process is crucial for automobile panel dies in order to achieve synergistic minimization of the environment impact, product quality, and processing efficiency. This paper presents a processing task-based evaluation method to optimize the cutting parameters, considering the trade-off among carbon emissions, surface roughness, and processing time. Three objective models and their relationships with the cutting parameters were obtained through input–output, response surface, and theoretical analyses, respectively. Examples of cylindrical turning were applied to achieve a central composite design (CCD), and relative validation experiments were applied to evaluate the proposed method. The experiments were conducted on the CAK50135di lathe cutting of AISI 1045 steel, and NSGA-II was used to obtain the Pareto fronts of the three objectives. Based on the TOPSIS method, the Pareto solution set was ranked to find the optimal solution to evaluate and select the optimal cutting parameters. An S/N ratio analysis and contour plots were applied to analyze the influence of each decision variable on the optimization objective. Finally, the changing rules of a single factor for each objective were analyzed. The results demonstrate that the proposed method is effective in finding the trade-off among the three objectives and obtaining reasonable application ranges of the cutting parameters from Pareto fronts.
Highlights
In 2017, the total number of automobiles in China reached 217 million, and has shown an increasing trend each year [1]
The design and manufacturing times of automobile panel dies accounts for 2/3 of the automobile development cycle [2], and the processing efficiency and quality of the die directly restrict the speed of an auto body modification
The results show that the parameter optimization has a significant energy saving effect, but shows little improvement of the surface roughness
Summary
In 2017, the total number of automobiles in China reached 217 million, and has shown an increasing trend each year [1]. The upgrading of cars has accelerated which has caused an acceleration of the need for automobile panel dies. The design and manufacturing times of automobile panel dies accounts for 2/3 of the automobile development cycle [2], and the processing efficiency and quality of the die directly restrict the speed of an auto body modification. There are large numbers of rotating machinery parts on the die. Turning is a necessary process for the machining of rotary. (2019) 32:94 substantial phase of reducing greenhouse gases in the international community [4] Eng. (2019) 32:94 substantial phase of reducing greenhouse gases in the international community [4]
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