Solutions for Sustainable Machining

2016 ◽  
Author(s):  
Eckart Uhlmann ◽  
Bernd Peukert ◽  
Simon Thom ◽  
Lukas Prasol ◽  
Paul Fürstmann ◽  
...  
Keyword(s):  
Machine Tools ◽  
High Performance ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
The United States ◽  
Dry Machining ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Sustainable Solutions ◽  
High Level

The manufacturing industry contributes over 19% to the world’s greenhouse gas emissions [1, 3] and 31% of the total energy consumed annually in the United States of America [2, 3]. There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitaet (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tools frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example for the aerospace industry.

scholarly journals Development of Optimal Design and Circular Broach Modular Design of Disc Cutters with the Development of a Parametric Model

2021 ◽  
pp. 15-21
Author(s):  
Ezekiel Oluwadamilare Akintona ◽  
Okeagu Fredrick ◽  
Nwufo Maduka Augustine
Keyword(s):  
Machine Tools ◽  
High Performance ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Modular Design ◽  
Cutting Tools ◽  
Work Piece ◽  
Geometrical Parameters ◽  
Disc Cutters ◽  
High Level

Cutting tool is one of the most important instruments in production. It is used for machining of different components on machine tools. A material is cut into a chip to incur the desired work piece surface currently used in engineering various cutting tools. The directions of development of structures of metal cutting tools are: higher precision of dimensional and geometrical parameters, the use of new tool materials, cost, and quick. The cutting tools are not only affected by the design of machine, technology of manufacturing of products, but also impact the constructive forms of machine parts. The emergence of mechanical spine, thanks to the pull method. Spine broach can provide high-performance processing spine bore with the required accuracy. The development of heavy machine tools required the creation of new designs of large instruments. The use of mechanical automatic lines also required design tools with high dimensional stability capable of handling the items within the specified tolerance for a certain time. Instruments were developed in the process of renewing the cutting edge of the cutting tools with automatic adjustment; setting up tools on the size of the machine is a device for automatic replacement of worn tool in the process line of the Computer-Aided Manufacturing CAM of the cutting tool special requirements. Equipment must operate with high level efficiency, so to reduce the loss of time resetting of the need to minimal. A cutting tool requires knowledge of the theoretical foundations of design and calculation tools using CAD.

Solutions for Sustainable Machining

2016 ◽  
Vol 139 (5) ◽  
Author(s):  
Eckart Uhlmann ◽  
Bernd Peukert ◽  
Simon Thom ◽  
Lukas Prasol ◽  
Paul Fürstmann ◽  
...  
Keyword(s):  
Machine Tool ◽  
Environmental Analysis ◽  
Machine Tools ◽  
Cutting Tool ◽  
Milling Machine ◽  
Dry Machining ◽  
Sustainable Machining ◽  
Sustainable Systems ◽  
Manufacturing Environments ◽  
Ieee International Symposium

The manufacturing industry contributes over 19% to the world's greenhouse gas emissions (U.S. Energy Information Administration, 2008, “Rep: Annual Energy Review 2008,” Report No. DOE/EIA-0384; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.) and 31% of the total energy consumed annually in the U.S. (Herzog, T., 2005, “World Greenhouse Gas Emissions in 2005,” World Resources Institute, Washington, DC 2; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.). There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitat (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tool frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example, for the aerospace industry.

Optimization of Control Gains in Numerical Control

2016 ◽  
Vol 1136 ◽  
pp. 651-654
Author(s):  
Hideki Aoyama ◽  
Duo Zhang
Keyword(s):  
Feed Rate ◽  
Machine Tools ◽  
Cutting Tool ◽  
Numerical Control ◽  
Machining Processes ◽  
Nc Program ◽  
Acceleration And Deceleration

It is frequently the case that the feed rate indicated in a numerical control (NC) program does not obtain in actual machining processes and the cutting tool does not path the points indicated in the NC. A reason underlying such problems is that control gains are not optimized, which causes issues with acceleration and deceleration in the control of machine tools. To address these problems, in this paper, we propose a method for the optimization of control gains using the MATLAB and Simulink software by considering the weight of the workpiece, the controlling distance, and the controlling speed. Simulations confirmed the effectiveness of our proposed optimization.

scholarly journals A Composite Evaluation Model of Sustainable Manufacturing in Machining Process for Typical Machine Tools

Processes ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 110 ◽  
Author(s):  
Lishu Lv ◽  
Zhaohui Deng ◽  
Tao Liu ◽  
Linlin Wan ◽  
Wenliang Huang ◽  
...  
Keyword(s):  
Energy Efficiency ◽  
Machine Tools ◽  
Manufacturing Industry ◽  
Orthogonal Experiment ◽  
Evaluation Model ◽  
Sustainable Manufacturing ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Carbon Efficiency

Machine tool is the basic manufacturing equipment in today’s mechanical manufacturing industry. A considerable amount of energy and carbon emission are consumed in machining processes, the realization of sustainable manufacturing of machine tools have become an urgent problem to be solved in the field of industry and academia. Therefore, five types of machine tools were selected for the typical machining processes (turning, milling, planning, grinding and drilling). Then the model of the energy efficiency, carbon efficiency and green degree model were established in this paper which considers the theory and experiment with the resource, energy and emission modeling method. The head frame spindle and head frame box were selected to verify the feasibility and practicability of the proposed model, based on the orthogonal experiment case of the key machining process. In addition, the influence rules of machining parameters were explored and the energy efficiency and green degree of the machine tools were compared. Finally, the corresponding strategies for energy conservation and emission reduction were proposed.

scholarly journals Sustainable Lubrication Methods for the Machining of Titanium Alloys: An Overview

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3852 ◽  
Author(s):  
Enrique García-Martínez ◽  
Valentín Miguel ◽  
Alberto Martínez-Martínez ◽  
María Carmen Manjabacas ◽  
Juana Coello
Keyword(s):  
Titanium Alloys ◽  
Cutting Tool ◽  
Chemical Components ◽  
Thermal Gradients ◽  
Dry Machining ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Modern Manufacturing ◽  
High Pressure Coolant ◽  
Very High

Titanium is one of the most interesting materials in modern manufacturing thanks to its good mechanical properties and light weight. These features make it very attractive for use in the aeronautical and aerospace industries. Important alloys, such as Ti6Al4V, are extensively used. Nevertheless, titanium alloys present several problems in machining processes. Their machinability is poor, affected by low thermal conductivity, which generates very high cutting temperatures and thermal gradients in the cutting tool. Lubricants and cutting fluids have traditionally been used to solve this problem. However, this option is unsustainable as such lubricants represent a risk to the environment and to the health of the operator due to their different chemical components. Therefore, novel, sustainable and green lubrication techniques are necessary. Dry machining is the most sustainable option. Nevertheless, difficult-to-machine materials like titanium alloys cannot be machined under these conditions, leading to very high cutting temperatures and excessive tool wear. This study is intended to describe, analyse and review the non-traditional lubrication techniques developed in turning, drilling and milling processes since 2015, including minimum quantity of lubricant, cryogenic lubrication, minimum quantity of cooling lubrication or high-pressure coolant. The aim is to provide a general overview of the recent advances in each technique for the main machining processes.

MEMS Inertial Technology for Aerospace Applications

2006 ◽  
Author(s):  
Eric J. Lautenschlager
Keyword(s):  
High Performance ◽  
Performance Metrics ◽  
Aerospace Industry ◽  
The United States ◽  
Future Goals ◽  
Aerospace Applications ◽  
Wide Range ◽  
Error Terms ◽  
High Level ◽  
And Control

The aerospace industry has guidance, navigation, and control needs which make use of a number of inertial technology systems. MEMS based solutions can offer several advantages over conventional technologies and are being developed for a wide range of applications. This paper will review the broad inertial applications that exist for the aerospace industry, identify some of the current non-MEMS technologies used to meet those needs, and then discuss what advantages MEMS based solutions can provide. This will be followed by a high level explanation of the general operating principles of a MEMS gyroscope, as well as identification of key performance metrics and error terms that are used for sensor evaluation. Finally, there will be a discussion of some basic design considerations, a review of the current state of the art for performance, and future goals and directions for inertial MEMS technologies. NOTICE: High performance inertial technology is subject to restrictions imposed by the International Traffic in Arms Regulations (ITARS), and Export Administration Regulations (EAR). The use of these technologies, or information pertaining to these technologies, may be restricted from foreign nationals of the United States.

scholarly journals A Novel Method of Sustainability Evaluation in Machining Processes

Processes ◽  
2019 ◽  
Vol 7 (5) ◽  
pp. 275 ◽  
Author(s):  
Haiming Sun ◽  
Conghu Liu ◽  
Jianqing Chen ◽  
Mengdi Gao ◽  
Xuehong Shen
Keyword(s):  
Conversion Efficiency ◽  
Manufacturing Industry ◽  
Energy Resource ◽  
Machining Process ◽  
Utilization Rate ◽  
Sustainability Evaluation ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Machining System ◽  
Improvement Method

In order to quantitatively evaluate and improve the sustainability of machining systems, this paper presents an emergy (the amount of energy consumed in direct and indirect transformations to make a product or service) based sustainability evaluation and improvement method for machining systems, contributing to the improvement of energy efficiency, resource efficiency and environmental performance, and realizing the sustainability development. First, the driver and challenge are studied, and the scope and hypothesis of the sustainable machining system are illustrated. Then, the emergy-based conversion efficiency model is proposed, which are (1) effective emergy utilization rate (EEUR), (2) emergy efficiency of unit product (EEUP) and (3) emergy conversion efficiency (ECE), to measure and evaluate the sustainable machining system from the perspectives of energy, resource and environment. Finally, the proposed model is applied to a vehicle-bridge machining process, and the results show that this paper provides the theoretical and method support for evaluating and improving the sustainable machining processes to decouple the resources and development of the manufacturing industry.

Quality Training and Research around the Machine Tools

2013 ◽  
Vol 759 ◽  
pp. 55-62
Author(s):  
A. Rodríguez ◽  
I. Tabernero ◽  
S. Martínez ◽  
Aitzol Lamikiz
Keyword(s):  
Machine Tools ◽  
High Performance ◽  
Milling Machine ◽  
Dual Use ◽  
New Students ◽  
Training And Research ◽  
High Level ◽  
Five Axis ◽  
Support Research

The best is to read these instructions and follow the outline of this text. The text area for your manuscript must be 17 cm wide and 25 cm high. The High Performance Manufacturing Group of the Faculty of Engineering of Bilbao has a workshop fully-equipped. In this way, these machine tools are valid both to support research carried out by the Group and also to improve teaching lessons, both theoretically and practically. In this paper, the case of a five-axis milling machine was presented and analyzed. Each year, the new students are taught to design various systems of the machine and they are also encouraged to make some practical tests. This dual use of machines is very useful since it allows to carry out high level researches, as well as to train new students in theoretical and practical issues.

scholarly journals Status-quo and Development of Cutting-tool Industry in Taiwan and China

2018 ◽  
Vol 11 (8) ◽  
pp. 90
Author(s):  
Jui-Lung Chen
Keyword(s):  
Machine Tools ◽  
Manufacturing Industry ◽  
High Efficiency ◽  
Cutting Tool ◽  
High Reliability ◽  
Cutting Tools ◽  
Academic Research ◽  
Policy Formulation ◽  
Expert Interview ◽  
Day By Day

Cutting plays a very important role in the manufacturing industry. The global industries of general machinery, automobile, aviation and aerospace, energy, medical, rail transit, mold and machine tools, etc. cannot do without cutting-tool equipment. Modern efficient cutting-tools focus on high accuracy, high efficiency, high reliability and customization. The type numbers and varieties of cutting-tools produced in Taiwan and China are becoming rich day by day. Therefore, this research explored the cutting-tool industry in Taiwan and China, and employed expert interview, five forces analysis, and PEST analysis to analyze the industry. This study offered conclusions based on the research results and provide specific, substantial business improvement, policy formulation and other related recommendations for relevant industry, government-related units and academic research.

Study on Minimum Quantity Lubrication Systems in Cooling of Machining Processes

2015 ◽  
Vol 809-810 ◽  
pp. 1022-1027 ◽  
Author(s):  
Ionel Olaru ◽  
Dragoş Iulian Nedelcu
Keyword(s):  
Machine Tools ◽  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Positive Influence ◽  
Nozzle Geometry ◽  
Machining Processes ◽  
Machined Surface ◽  
Cooling Systems ◽  
Cutting Operation

The cooling systems on machine tools are particularly important; these have a positive influence on the cutting operation and the quality of machined surface. A particular importance represent finding an optimal correlation between the lubricant and coolant used, the material to be processed, processing method and the cutting regime. A high temperature in the working area over a certain value allowable can be harmful in terms of both the resulted surface quality and repercussions on the life of the cutting tool. The parameters of the cooling-lubricating fluid flow can be influenced by the nature of the fluid or fluids, or the nozzle geometry used, which generally has a convergent-divergent geometry in order to achieve a better dispersion of the coolant/lubricant on the area to be machined.

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