A General Empirical Energy Consumption Model for Computer Numerical Control Milling Machine

2019 ◽  
Vol 141 (2) ◽  
Author(s):  
Yadan Zeng ◽  
Tonghui Li ◽  
Yelin Deng ◽  
Chris Yuan
Keyword(s):  
Experimental Data ◽  
Energy Consumption ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Milling Machine ◽  
Cnc Machines ◽  
Proposed Model ◽  
Absolute Residual

Energy consumption of computer numerical control (CNC) machines is significant and various empirical models have been developed to model the specific energy consumption (SEC) of CNC machines. However, most of the models are developed for specific machines and hence have limited applications in manufacturing industry. In this research, a general empirical SEC model for milling machine at certain power level is developed based on actual cutting experimental data. In this model, stand-by power and spindle power are used in the SEC model for the first time. The material removal rate (MRR) is used to represent the cutting parameter. The proposed model is fitted by the regression analysis and validated using experimental data. Results show that the proposed model can be applied on various milling machines with an average absolute residual ratio of 6%. The model is also validated through a series of cutting experiments on a machine center, with an accuracy of 91.5%, for the SEC calculation.

Numerical Modeling of Specific Energy Consumption in Machining Process

2013 ◽  
Author(s):  
Tonghui Li ◽  
Chris Yuan
Keyword(s):  
Energy Consumption ◽  
Specific Energy ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Machining Process ◽  
Application Range ◽  
Proposed Model ◽  
Energy Consumption Prediction ◽  
Spindle Power ◽  
Consumption Prediction

Prediction and estimation of energy consumption of machining process are important for the optimization of the machining process and the environmental impact of manufacturing. Two energy consumption models are proposed in this paper. A novel numerical model is presented to roughly estimate the specific energy consumption (SEC) of a machining process based on the nameplate spindle power of the machine and the material removal rate (MRR). This model is validated and analyzed by experimental data from a variety of sources. The application range of the proposed model has been investigated. Another accurate SEC model, which is based on a specific machine and machine tool, is established for accurate energy consumption prediction. The accurate model is tested to have a confidence range of 97%.

scholarly journals Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 939 ◽  
Author(s):  
Amelia Nápoles Alberro ◽  
Hernán González Rojas ◽  
Antonio Sánchez Egea ◽  
Saqib Hameed ◽  
Reyna Peña Aguilar
Keyword(s):  
Energy Consumption ◽  
Material Removal Rate ◽  
Specific Energy ◽  
Chip Formation ◽  
Material Removal ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Industrial Scale ◽  
Depth Of Cut ◽  
Grinding Process

Grinding energy efficiency depends on the appropriate selection of cutting conditions, grinding wheel, and workpiece material. Additionally, the estimation of specific energy consumption is a good indicator to control the consumed energy during the grinding process. Consequently, this study develops a model of material-removal rate to estimate specific energy consumption based on the measurement of active power consumed in a plane surface grinding of C45K with different thermal treatments and AISI 304. This model identifies and evaluates the dissipated power by sliding, ploughing, and chip formation in an industrial-scale grinding process. Furthermore, the instantaneous positions of abrasive grains during cutting are described to study the material-removal rate. The estimation of specific chip-formation energy is similar to that described by other authors on a laboratory scale, which allows to validate the model and experiments. Finally, the results show that the energy consumed by sliding is the main mechanism of energy dissipation in an industrial-scale grinding process, where it is denoted that sliding energy by volume unity decreases as the depth of cut and the speed of the workpiece increase.

scholarly journals All in the Family

2002 ◽  
Vol 124 (02) ◽  
pp. 56-58 ◽  
Author(s):  
John DeGaspari
Keyword(s):  
Automotive Industry ◽  
Machine Tools ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Transfer Lines ◽  
Cnc Machines ◽  
Reconfigurable Machining ◽  
The Family ◽  
High Degree ◽  
Control Machine

This article focuses on reconfigurable machining systems. These systems have lately caught the attention of some manufacturers who need something that is more flexible than a dedicated line and produces goods faster than a shop of CNC machines. The lines are called reconfigurable because they consist of modules and, once they are programmed, can be switched quickly to turn out different, but similar pieces from a family of products. Proponents say that reconfigurable machining systems have carved out a niche between two other alternatives—dedicated transfer lines, which are optimized for producing large volumes of specific parts, and computer numerical control machine tools, which have a high degree of flexibility but are slower to finish products. Reconfigurable machining systems have been developed for the automotive industry, for instance, as car companies have increasingly outsourced their production to tier-one suppliers and demanded price reductions.

Optimal Design for Rice Straw Briquetting Process Based on Experiments

2016 ◽  
Author(s):  
Yu Wang ◽  
Yu Sun ◽  
Kai Wu ◽  
Xianfei Xia
Keyword(s):  
Experimental Data ◽  
Energy Consumption ◽  
Moisture Content ◽  
Rice Straw ◽  
Lower Energy ◽  
Optimization Design ◽  
Specific Energy Consumption ◽  
Agricultural Crop ◽  
Technological Parameters ◽  
Test Platform

Ineffective utilization of agricultural crop straw is a big problem in agricultural developing countries. In this study, optimization design was carried out for the rice straw briquetting process based on experiments. A briquetting test platform designed by the authors was used to measure the specific energy consumption, extrusion pressure, as well as the density and compressive strength of the products made by rice straw under different technological parameters. These parameters included moisture content, temperature, pressure and pressing speed. Finally, optimal technological parameters were provided based on the experimental data. Results show that, lower energy consumption and better products quality are achieved when the moisture content is within 15% ∼ 20%, the temperature is within 110 °C ∼ 120 °C, the pressure is within 50 MPa ∼ 60 MPa and the pressing speed is within 40 mm/min ∼ 60 mm/min.

Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-Axis Machining Center

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Ryuta Sato ◽  
Keiichi Shirase ◽  
Akio Hayashi
Keyword(s):  
Energy Consumption ◽  
Minimum Energy ◽  
Numerical Control ◽  
Total Energy Consumption ◽  
Feed Drive ◽  
Machining Center ◽  
Proposed Model ◽  
Energy Consumptions ◽  
Drive Systems ◽  
Five Axis

Energy consumption of numerical control (NC) machine tools is one of the key issues in modern industrial field. This study focuses on reducing the energy consumed by a five-axis machining center by changing only the workpiece setting position. Previous studies show that the movements along each axis in five-axis machining centers depend on the workpiece setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece setting position that can minimize the energy consumed during these motions is assumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five-axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting position on the energy consumption is investigated by employing the cone-frustum cutting motion with simultaneous five-axis motions. The energy consumption that depends on the workpiece setting position is first measured and then estimated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece setting position; the minimum energy consumption is found to be 20% lower than the maximum one.

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