Modeling and analysis of specific cutting energy of whirling milling process based on cutting parameters

Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

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Proper selection of cutting parameters and cutting tool angle to lower the specific cutting energy during high speed machining of 7050-T7451 aluminum alloy

Journal of Cleaner Production ◽

10.1016/j.jclepro.2016.04.071 ◽

2016 ◽

Vol 129 ◽

pp. 292-304 ◽

Cited By ~ 40

Author(s):

Bing Wang ◽

Zhanqiang Liu ◽

Qinghua Song ◽

Yi Wan ◽

Zhenyu Shi

Keyword(s):

Aluminum Alloy ◽

High Speed ◽

Cutting Tool ◽

Cutting Parameters ◽

High Speed Machining ◽

Specific Cutting Energy ◽

Proper Selection ◽

Cutting Energy ◽

Selection Of ◽

Tool Angle

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Experimental Investigation on Machinability of Polypropylene Reinforced with Miscanthus Fibers and Biochar

Materials ◽

10.3390/ma13051181 ◽

2020 ◽

Vol 13 (5) ◽

pp. 1181

Author(s):

Dinh Son Tran ◽

Victor Songmene ◽

Anh Dung Ngo ◽

Jules Kouam ◽

Arturo Rodriguez-Uribe ◽

...

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

Ultrafine Particles ◽

Thrust Force ◽

Experimental Studies ◽

Cutting Parameters ◽

Drill Bit ◽

Machining Parameters ◽

Specific Cutting Energy ◽

Cutting Energy

The machinability of composite materials depends on reinforcements, matrix properties, cutting parameters, and on the cutting tool used (material, coating, and geometry). For new composites, experimental studies must be performed in order to understand their machinability, and thereby help manufacturers establishing appropriate cutting data. In this study, investigations are conducted to analyze the effects of cutting parameters and drill bit diameter on the thrust force, surface roughness, specific cutting energy, and dust emission during dry drilling of a new hybrid biocomposite consisting of polypropylene reinforced with miscanthus fibers and biochar. A full factorial design was used for the experimental design. It was found that the feed rate, the spindle speed, and the drill bit diameter have significant effects on the thrust force, the surface roughness, and the specific cutting energy. The effects of the machining parameters and the drill bit diameter on ultrafine particles emitted were not statistically significant, while the feed rate and drill bit diameter had significant effects on fine particle emission.

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Numerical Investigation of the Rock Cutting Performance of a Circular Sawblade

Mathematical Problems in Engineering ◽

10.1155/2020/9706183 ◽

2020 ◽

Vol 2020 ◽

pp. 1-18

Author(s):

Zhiwen Wang ◽

Qingliang Zeng ◽

Zhenguo Lu ◽

Zhihai Liu ◽

Xu Li

Keyword(s):

Cutting Force ◽

Great Influence ◽

Cutting Parameters ◽

Simulation Method ◽

Rock Cutting ◽

Rock Breaking ◽

Feed Speed ◽

Specific Cutting Energy ◽

Cutting Depth ◽

Cutting Energy

The rock cutting process with a circular sawblade and the rock breaking mechanism of rock are studied with a numerical simulation method in this paper. The influence of cutting parameters of the circular sawblade on cutting force, rock damage, and specific cutting energy in the process of circular sawblade cutting rock is researched. The cutting force increases with the feed speed and an increase in cutting depth and decline in rotation speed. Cutting rock with double circular sawblades can reduce cutting force. However, the specific cutting energy declines with the increase in cutting depth and the decline in the distance between the double circular sawblades. Cutting parameters have a great influence on the damage range of rock. The research results can be applied to rock processing with a circular sawblade.

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Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method

Materials ◽

10.3390/ma13030567 ◽

2020 ◽

Vol 13 (3) ◽

pp. 567 ◽

Cited By ~ 3

Author(s):

Luis C. Flórez García ◽

Hernán A. González Rojas ◽

Antonio J. Sánchez Egea

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Carbon Steel ◽

Cutting Parameters ◽

Machining Process ◽

Specific Cutting Energy ◽

The Finite Element Method ◽

Turning Process ◽

Cutting Energy ◽

Element Method

The objective of this work is to analyze the influence of the vibration-assisted turning process on the machinability of S235 carbon steel. During the experiments using this vibrational machining process, the vibrational amplitude and frequency of the cutting tool were adjusted to drive the tool tip in an elliptical or linear motion in the feed direction. Furthermore, a finite element analysis was deployed to investigate the mechanical response for different vibration-assisted cutting conditions. The results show how the specific cutting energy and the material’s machinability behave when using different operational cutting parameters, such as vibration frequency and tool tip motion in the x-axis, y-axis, and elliptical (x-y plane) motion. Then, the specific cutting energy and material’s machinability are compared with a conventional turning process, which helps to validate the finite element method (FEM) for the vibration-assisted process. As a result of the operating parameters used, the vibration-assisted machining process leads to a machinability improvement of up to 18% in S235 carbon steel. In particular, higher vibration frequencies were shown to increase the material’s machinability due to the specific cutting energy decrease. Therefore, the finite element method can be used to predict the vibration-assisted cutting and the specific cutting energy, based on predefined cutting parameters.

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An analytical model for predicting specific cutting energy in whirling milling process

Journal of Cleaner Production ◽

10.1016/j.jclepro.2019.118181 ◽

2019 ◽

Vol 240 ◽

pp. 118181 ◽

Cited By ~ 3

Author(s):

Yan He ◽

Lexiang Wang ◽

Yulin Wang ◽

Yufeng Li ◽

Shilong Wang ◽

...

Keyword(s):

Analytical Model ◽

Milling Process ◽

Specific Cutting Energy ◽

Cutting Energy

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Numerical Simulation of Rock Cutting with a Diamond Sawblade Based on LS-DYNA

Mathematical Problems in Engineering ◽

10.1155/2019/6462909 ◽

2019 ◽

Vol 2019 ◽

pp. 1-15

Author(s):

Zhiwen Wang ◽

Qingliang Zeng ◽

Zhenguo Lu ◽

Lirong Wan ◽

Xin Zhang

Keyword(s):

Numerical Simulation ◽

Hard Rock ◽

Great Influence ◽

Cutting Parameters ◽

Rock Cutting ◽

Feed Speed ◽

Specific Cutting Energy ◽

Cutting Depth ◽

Cutting Energy ◽

Diamond Sawblade

Aiming at the complex nonlinear dynamic problem of cutting hard rock with diamond sawblades, the process of hard rock cutting with a diamond sawblade was studied based on ANSYS/LS-DYNA. A numerical simulation model of a diamond sawblade cutting hard rock with different rotation speeds, feed speeds, and cutting depths was established to study the effects of the cutting parameters on the cutting force and specific cutting energy consumption and on the damage to the rock. The numerical simulation results demonstrated that the feed speed and cutting depth of the diamond saw are quadratically correlated with the cutting force, but the rotation speed is negatively linearly correlated. The damage region of the rock is positively correlated with the feed speed and cutting depth of the diamond sawblade and has a negative correlation with the rotation velocity. The cutting parameters have a great influence on specific cutting energy consumption. Analysis of the relationship among the cutting parameters and the specific cutting energy with multivariate linear fitting indicated that the cutting speed and cutting depth have a great influence on the cutting energy.

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Research on cutting performance and fatigue life of conical pick in cutting rock process

Science Progress ◽

10.1177/00368504211050293 ◽

2021 ◽

Vol 104 (4) ◽

pp. 003685042110502

Author(s):

Qingliang Zeng ◽

Zhiwen Wang ◽

Zhenguo Lu ◽

Lirong Wan ◽

Zhihai Liu ◽

...

Keyword(s):

Fatigue Life ◽

Cutting Force ◽

Cutting Speed ◽

Simulation Models ◽

Cutting Parameters ◽

Rock Damage ◽

Specific Cutting Energy ◽

Conical Pick ◽

Research Results ◽

Cutting Energy

The conical pick is the most crucial tool of roadheader for breaking rock, establishing the conical pick cutting rock and conical pick fatigue life numerical simulation models to investigate the influence of cutting parameters on rock damage, average peak cutting force, specific cutting energy and the conical pick fatigue life. The research results indicate that the width and depth of rock damage increase with increasing cutting depth and cutting speed. The average peak cutting force and the specific cutting energy have the same changing tendency. The changing trend of conical pick fatigue life and conical pick stress is opposite relationship. The optimum cutting angle of the conical pick cutting rock is 45°. Applying the research results for guiding the optimization of the cutting parameters reduces the specific cutting energy and stress and improves the conical pick fatigue life.

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