Abstract
In the dimension stone industry, predicting the energy consumption in rock cutting process and examining its relationship with machining parameters are among the most important steps to achieve the optimum conditions in terms of energy consumption. A laboratory scale cutting machine with changing machining parameters was made and its energy consumption was evaluated through the statistical analysis. Tests were carried on seven carbonate rock samples under different operating conditions at different depths of cut, feed rates and peripheral speeds. Finally, an energy consumption model was obtained through statistical studies using SPSS software. The t and F tests were used to validate the model and to control each of the independent variables. To see the prediction capability of the derived model, the scatter diagram of the observed and estimated values was plotted. The results showed that the points are very close to the 1:1 diagonal straight line. It concluded that the developed model has a high degree of accuracy with a high correlation between the predicted and the observed values. Due to its high accuracy, the proposed model can be used in the calculation of energy consumption under various operating parameters.
Highlights
Improving the efficiency of energy consumers for the proper use of energy resources is one of the most important issues of recent studies
The results showed that the points are very close to the 1:1 diagonal straight line
The diamond segments move on the cutting surface, which results in the formation of a stone chip due to the penetration of the diamond grains into the rock
Summary
These changeable forces together with the posts and heights at the workpiece surface, discontinuous thickness of the chips, the chips cracking and the layering, the friction between the surfaces change the cutting conditions. Factors affecting the cutting performance can be evaluated in two main sections:. (1) Workpiece (stone) related studies: In this context, several experimental models and several sorted samples are presented to anticipate the cutting ability according to the mechanical and physical characteristics (valid references). (2) Cutting characteristics (machine, cutter and cutting method): Cutting plot characteristics include workpiece feed rate (Fr), peripheral speed (Ps), depth of cut (Dc), disk (B), segment (S) and the cutting method (M). The best cutting performance occurs by choosing a suitable feed rate, peripheral speed, cutting depth, diamond tools and an appropriate cutting method. R.; Sohrabian, B.; Ataei, M. statistical studies were done on the experimental results and a model was introduced for predicting the energy consumption. The results are presented and a conclusion is given
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