Energy Savings for Sustainability of Machining Process

2015 ◽  
Author(s):  
Ganesh Bharambe ◽  
Prakash Dabeer ◽  
Kumar Digambar Sapate ◽  
Suresh M. Sawant
Keyword(s):  
Energy Consumption ◽  
Material Handling ◽  
Metal Cutting ◽  
Energy Savings ◽  
Specific Energy Consumption ◽  
Cutting Tools ◽  
Machining Process ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Set Up

Processing of metals in industries is lifeline of economy of country, which helps to shape the country. Energy saving in this process is attributed to both the parts ie process of machining and energy consumed in machine tools itself. The process of material removal had experienced lot of improvements in last few decades. This consists of developments in pre-machining processes, metal cutting methods and developments in cutting theories and cutting tools. Cutting fluid is one of challenging field to yield more favourable results. Manufacturing practices beyond its existing limits, process and machine automations, using the previous data for improving machinabilities, optimizing through relative benchmarks (a market driven schemes) shall lead the manufacturing speed to a new high. Adaptibility of manufacturing set up to absorb new requirement will also be a controlling factor for acceleration of manufacturing processes. This paper discusses the efforts to reduce the energy to produce a product. Various methods are discussed to minimize the energy consumed for driving the machine components such as spindle, feeding device, lubricating system, cutting fluid system, indexing and tooling management, speed and feed controlling devices etc. Different requirements such as friction energy in braking action, speed reducing or cushioning will also consume certain amount of energy during its operations. Therefore one has to understand the various types of energy flows and classification of energy forms used from place to place. Study of constructional features of machines brings a lot of opportunities for savings in energy. The concepts of material handling, fluid handling like hydraulic and pneumatic circuits, lubrication system, shall also provide the opportunities for savings in energy consumption. Energy used for working of accessories whether they are required at that particular moments needs to be considered from time to time. There are few more methods for locating the chances for arresting the energy wastages and reducing specific energy consumption referring a particular process or function. Previous data generated for similar functions can be referred for comparison and efforts can be added to reduce the requirement of energy. Efficient and effective utilization of equipment shall open a fresh path for finding the energy reductions. Sustainability of machining processes can be ensured for future using the lean energy utilizations for productions. Authors have explained the live cases to demonstrate reduction in energy consumption. Few potential guidelines are also narrated in this line. Further few cases are discussed from literature survey which support and will help to pursue the target.

Assessment of the Adequacy of the Definition of Cutting Forces for the Purpose of Minimizing Energy Consumption in Machining Processes

2019 ◽  
Vol 945 ◽  
pp. 556-562
Author(s):  
A.G. Kondrashov ◽  
D.T. Safarov ◽  
R.R. Kazargeldinov
Keyword(s):  
Energy Consumption ◽  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Electrical Power ◽  
Cutting Tools ◽  
Precise Determination ◽  
Machining Processes ◽  
Milling Operations ◽  
Cutting Equipment

Minimizing energy consumption in the processing of parts on metal-cutting equipment is most effective at the stage of designing the content of operations. Important in this process is the precise determination of the initial parameters - cutting forces. This parameter allows you to plan both energy consumption and perform additional calculations for the deformation of the tooling and workpiece in order to predict the geometric accuracy of the machined part. The article presents the results of experiments on measuring the circumferential cutting force during milling operations of an aluminum alloy workpiece with an end mill. The measurements were carried out by an indirect method - by recording the electrical power on the spindle and then calculating the circumferential cutting force. Theoretical analysis of the methods of calculation of cutting forces showed significant differences between the results obtained by domestic methods and recommendations of world manufacturers of cutting tools. Statistical analysis of the results of calculations based on reference data and measurements made it possible to assess the adequacy of the known methods for calculating cutting forces in order to minimize energy consumption in operations of processing parts on metal-cutting equipment

Nano-lubricant influence on surface residual stresses in hard milling

2021 ◽  
pp. 095440892110047
Author(s):  
Omid Rohani Raftar ◽  
Mahdi Kaveh ◽  
Mohsen Khajehzadeh ◽  
Abdolreza Rahimi ◽  
Mohammad Reza Razfar
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Mechanical Loading ◽  
Metal Cutting ◽  
Water Soluble ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Surface Residual Stresses

Residual stress could be induced by machining processes like milling which can greatly affect the fatigue life of fabricated parts, especially in dynamic loading conditions. In metal cutting operations, machining induced residual stresses can be explained in the terms of machining forces and temperatures of the cutting zones. This thermo mechanical loading along with the resulted metallurgical changes are the main sources of residual stresses generation at the surface of machined workpiece. Researchers have proved the superior properties of nanofluids over the conventional coolants to reduce the intensity of thermo mechanical loading in machining process which will affect the residual stresses caused by machining. Therefore, in this paper, silver nanoparticles in the water-soluble oil have been used for reducing the mechanical and thermal loads in the milling process. The cutting forces, temperature of the cutting zone, surface roughness and the residual stress of machined surface have been measured experimentally in milling of hardened steel AISI 4140 for various nanoparticle’s concentration, feeds and cutting speeds. Results show that increasing the concentration of Nano-particles in base fluid from 0.5 to 3.0% wt., will make machining surface residual stresses more compressive averagely by about 66.67% compared to conventional cutting fluid.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Energy efficient cutting parameter optimization

2021 ◽  
Author(s):  
Xingzheng Chen ◽  
Congbo Li ◽  
Ying Tang ◽  
Li Li ◽  
Hongcheng Li
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Parameter Optimization ◽  
Energy Efficient ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Current Status ◽  
Cutting Parameter ◽  
Cutting Parameter Optimization

AbstractMechanical manufacturing industry consumes substantial energy with low energy efficiency. Increasing pressures from energy price and environmental directive force mechanical manufacturing industries to implement energy efficient technologies for reducing energy consumption and improving energy efficiency of their machining processes. In a practical machining process, cutting parameters are vital variables set by manufacturers in accordance with machining requirements of workpiece and machining condition. Proper selection of cutting parameters with energy consideration can effectively reduce energy consumption and improve energy efficiency of the machining process. Over the past 10 years, many researchers have been engaged in energy efficient cutting parameter optimization, and a large amount of literature have been published. This paper conducts a comprehensive literature review of current studies on energy efficient cutting parameter optimization to fully understand the recent advances in this research area. The energy consumption characteristics of machining process are analyzed by decomposing total energy consumption into electrical energy consumption of machine tool and embodied energy of cutting tool and cutting fluid. Current studies on energy efficient cutting parameter optimization by using experimental design method and energy models are reviewed in a comprehensive manner. Combined with the current status, future research directions of energy efficient cutting parameter optimization are presented.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

Investigations on the Application of Minimum Quantity Solid Lubrication in Turning

2017 ◽  
Author(s):  
Mayur A. Makhesana ◽  
Kaushik M. Patel
Keyword(s):  
Tool Wear ◽  
Cost Effective ◽  
Solid Lubricants ◽  
Cutting Fluid ◽  
Solid Lubrication ◽  
Machining Processes ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Set Up ◽  
Experimental Findings

Machining is the manufacturing process, capable of producing required shape and size by material removal. In recent times industries are striving to enhance the performance of machining processes. One of the problem associated with machining is the amount of heat generation as a result of friction between tool and workpiece. Heat generated may affect the quality of machined surface and tool wear. In order to control it, cutting fluid is applied in large quantity. The problem arises with the use of cutting fluid is its effect on worker’s health and environment. The present investigation is an attempt to explore the use the solid lubricants in machining as an alternative to cutting fluid. The work involves development of minimum quantity solid lubrication set up. Turning experiments has been performed by applying solid lubricants mixed with cutting fluid in minimum quantity. The performance of minimum quantity solid lubrication has been assessed in form of obtained surface finish, power consumption and tool wear during turning. Experimental findings discovered the superiority of minimum quantity solid lubrication over conventional cutting fluid and can be considered as cost effective and sustainable lubrication method.

scholarly journals A Novel Experimental Test Bench to Investigate the Effects of Cutting Fluids on the Frictional Conditions in Metal Cutting

2020 ◽  
Vol 4 (2) ◽  
pp. 45 ◽  
Author(s):  
Thomas Lakner ◽  
Marvin Hardt
Keyword(s):  
Experimental Test ◽  
Metal Cutting ◽  
Test Bench ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Workpiece Material ◽  
Fluid Supply ◽  
Frictional Forces ◽  
Experimental Test Bench

The tribological effect of cutting fluids in the machining processes to reduce the friction in the cutting zone is still widely unknown. Most test benches and procedures do not represent the contact conditions of machining processes adequately, especially for interrupted contacts. This results in a lack of knowledge of the tribological behavior in machining processes. To close this knowledge gap, a novel experimental test bench to investigate the effects of cutting fluids on the frictional conditions in metal cutting under high-pressure cutting fluid supply was developed and utilized within this work. The results show that there is a difference between the frictional forces in interrupted contact compared to continuous contact. Furthermore, the cutting fluid parameters of supply pressure, volumetric flow rate, and impact point of the cutting fluid jet influence the frictional forces, the intensities of which depend on the workpiece material. In conclusion, the novel test bench allows examining the frictional behavior in interrupted cuts with an unprecedented precision, which contributes to a knowledge-based design of the cutting fluid supply for cutting tools.

scholarly journals Benchmarking of energy consumption in municipal wastewater treatment plants – a survey of over 200 plants in Italy

2018 ◽  
Vol 77 (9) ◽  
pp. 2242-2252 ◽  
Author(s):  
M. Vaccari ◽  
P. Foladori ◽  
S. Nembrini ◽  
F. Vitali
Keyword(s):  
Wastewater Treatment ◽  
Energy Consumption ◽  
Municipal Wastewater ◽  
Energy Savings ◽  
Wastewater Treatment Plants ◽  
Specific Energy Consumption ◽  
Oxygen Demand ◽  
Energy Performance ◽  
High Energy ◽  
Municipal Wastewater Treatment

Abstract One of the largest surveys in Europe about energy consumption in Italian wastewater treatment plants (WWTPs) is presented, based on 241 WWTPs and a total population equivalent (PE) of more than 9,000,000 PE. The study contributes towards standardised resilient data and benchmarking and to identify potentials for energy savings. In the energy benchmark, three indicators were used: specific energy consumption expressed per population equivalents (kWh PE−1 year−1), per cubic meter (kWh/m3), and per unit of chemical oxygen demand (COD) removed (kWh/kgCOD). The indicator kWh/m3, even though widely applied, resulted in a biased benchmark, because highly influenced by stormwater and infiltrations. Plants with combined networks (often used in Europe) showed an apparent better energy performance. Conversely, the indicator kWh PE−1 year−1 resulted in a more meaningful definition of a benchmark. High energy efficiency was associated with: (i) large capacity of the plant, (ii) higher COD concentration in wastewater, (iii) separate sewer systems, (iv) capacity utilisation over 80%, and (v) high organic loads, but without overloading. The 25th percentile was proposed as a benchmark for four size classes: 23 kWh PE−1 y−1 for large plants > 100,000 PE; 42 kWh PE−1 y−1 for capacity 10,000 < PE < 100,000, 48 kWh PE−1 y−1 for capacity 2,000 < PE < 10,000 and 76 kWh PE−1 y−1 for small plants < 2,000 PE.

Energy Reduction and Optimisation in Membrane Bioreactor Systems

2010 ◽  
Vol 5 (4) ◽  
Author(s):  
Guihe Tao ◽  
Kiran Kekre ◽  
Maung Htun Oo ◽  
Bala Viswanath ◽  
Aliman MD Yusof ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Specific Energy ◽  
Energy Efficient ◽  
Specific Energy Consumption ◽  
Pilot Scale ◽  
Energy Reduction ◽  
Energy Audit ◽  
Membrane Flux ◽  
Demonstration Plant ◽  
Set Up

One of the major components of MBR operating expenditure is energy consumption. This paper presents our six-year journey of energy reduction and optimization in MBR systems through various pilot and demonstration studies. Through comprehensive and systematic MBR optimisation studies, the specific energy consumption was reduced from 1.3 kWh m−3 to less than 0.8 kWh m−3 by increasing membrane flux and reducing aeration at 300 m3 per day pilot scale plants. Through energy audit, the key energy consumption components including process aeration, membrane scouring rate, SRT, MLSS level, MLSS recirculation, and energy efficient equipment selection were identified, and these were optimised one by one at 23,000 m3 per day municipal scale MBR demonstration plant after the baseline had been set up. The specific energy consumption was further reduced to 0.37 kWh m−3.

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