scholarly journals Identifying Direct Electrical Energy Demand in Wire-Cut EDM

2020 ◽  
Vol 39 (1) ◽  
pp. 171-178
Author(s):  
Anis Fatima ◽  
Amir Iqbal Syed
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Energy Demand ◽  
Copper Wire ◽  
Electrical Energy ◽  
Working Fluid ◽  
Work Piece ◽  
Main Concern ◽  
Product Cycle ◽  
Machining Processes

Non-traditional machining processes are popular for generating complex features on the work piece. With advances in material engineering, new ways of cutting technologies has been emerged. However, EDM (Electric Discharge Machining) has gained recognition for producing extraordinary surface finished, intricate part geometries with accuracy and its ability to cut through difficult to machined materials. However, like every product cycle, manufacturing processes also require energy to convert raw materials into finished product. In manufacturing operations, energy input gives carbon footprints which have an effect on our environment. It is observed that reducing energy consumption is becoming the main concern of manufacturers because of enforcing environmental laws and due to the economics of the processing. It is argued that world’s 70% of energy consumption is consumed by manufacturing sector. The aim of the work was to identify direct energy demands in wire cut EDM. The variability in energy demand was explored by operating wire cut EDM at no-load and loaded conditions.Stainless steel S304 was used as a work piece. Experiments were performed on three different wire-cut EDM.Molybdenum wire, brass wire and copper wire were used as an electrode wire and distilled water was used as a working fluid. During the experiment, electrical current was measured and the variation of power requirement was evaluated. Power required by different features of EDM was compared with the existing energy models and factors were identified that consume most of the electrical energy. Further, a comparison is made between traditional and non-traditional machining processes. This contribution will help to assess energy efficiency of EDM technology and identify priority areas for improvements. This work is also significant for machine tool designers for optimum utilization of energy,reduced environmental impact and reduced production cost of their machine tool.

scholarly journals Numerical Modeling and Experimental Validation in Orthogonal Machining of Aluminum Al 6061-T6 Alloy

2020 ◽  
Vol 39 (1) ◽  
pp. 179-194
Author(s):  
Suhail Akram ◽  
Shafi uddin ◽  
Syed Hussain Imran Jaffery ◽  
Mian Aamir Jalil ◽  
Syed Waqar Hyder Kazmi
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Energy Demand ◽  
Copper Wire ◽  
Working Fluid ◽  
Work Piece ◽  
Main Concern ◽  
Product Cycle ◽  
Machining Processes ◽  
Power Requirement

Non-traditional machining processes are popular for generating complex features on the work piece. With advances in material engineering, new ways of cutting technologies has been emerged. However, EDM (Electric Discharge Machining) has gained recognition for producing extraordinary surface finished, intricate part geometries with accuracy and its ability to cut through difficult to machined materials. However, like every product cycle, manufacturing processes also require energy to convert raw materials into finished product. In manufacturing operations, energy input gives carbon footprints which have an effect on our environment. It is observed that reducing energy consumption is becoming the main concern of manufacturers because of enforcing environmental laws and due to the economics of the processing. It is argued that world’s 70% of energy consumption is consumed by manufacturing sector. The aim of the work was to identify direct energy demands in wire cut EDM. The variability in energy demand was explored by operating wire cut EDM at no-load and loaded conditions.Stainless steel S304 was used as a work piece. Experiments were performed on three different wire-cut EDM.Molybdenum wire, brass wire and copper wire were used as an electrode wire and distilled water was used as a working fluid. During the experiment, electrical current was measured and the variation of power requirement was evaluated. Power required by different features of EDM was compared with the existing energy models and factors were identified that consume most of the electrical energy. Further, a comparison is made between traditional and non-traditional machining processes. This contribution will help to assess energy efficiency of EDM technology and identify priority areas for improvements. This work is also significant for machine tool designers for optimum utilization of energy,reduced environmental impact and reduced production cost of their machine tool.

Energy Demand Simulation of Machine Tools with Improved Chatter Stability Achieved by Active Damping

2015 ◽  
Vol 805 ◽  
pp. 187-195
Author(s):  
Robin Kleinwort ◽  
Richard S.H. Popp ◽  
Benedict Cavalié ◽  
Michael F. Zaeh
Keyword(s):  
Energy Consumption ◽  
Total Energy ◽  
Machine Tools ◽  
Energy Demand ◽  
Removal Rate ◽  
Active Damping ◽  
Depth Of Cut ◽  
Chatter Stability ◽  
Machining Processes ◽  
Base Load

The electric base load of milling machine tools has a high share of the machine’s total energy consumption. An approach to decrease the energy demand per workpiece is to shorten the machining time by raising the material removal rate. The maximum feed depends on the tool’s wear resistance while the maximum depth of cut is often limited by the chatter stability of the machine. In this paper active damping is used to damp chatter vibrations, which leads to a higher depth of cut. To evaluate the decrease of energy consumption for any workpiece, a modeling methodology for the energy demand of machine tools was developed, which is presented in this paper. The methodology is able to estimate the energy requirements of the spindle during cutting, of the feed drives, of the auxiliary equipment and of the base load. The numerical results were experimentally validated by different 2.5D machining processes, with good agreement between the simulation model and the experimental results. Therefore, the proposed methodology can be used effectively for calculating the total energy required for the machining of any workpiece. In addition, the structural dynamics of the machine tool, the active damping system and the cutting process were modeled in order to simulate the chatter stability. This enables a straightforward determination of the optimum cutting parameters as well as a comparison of different milling part programs, both in terms of the energy demand. Furthermore, it is possible to evaluate the energy conservation by active damping and to point out for which cutting processes active damping is useful.

scholarly journals Present Situation of Electrical Energy Demand, Supply, Projection of Demand-supply and Renewable Energy Utilization and Progress

2020 ◽  
Author(s):  
Md Nazmul Islam
Keyword(s):  
Renewable Energy ◽  
Energy Consumption ◽  
Energy Demand ◽  
Electrical Energy ◽  
Present Situation ◽  
Energy Utilization ◽  
Economic Activities ◽  
Power Development ◽  
Per Capita ◽  
Renewable Energy Generation

<p>A brief overview of present electricity demand, supply, projection of them and renewable energy generation and progress has been presented in this paper. Electricity is the major source of power for most of the country's economic activities. According to the Bangladesh Power Development Board in July 2018, 90 percent of the population had access to electricity. However per capita energy consumption in Bangladesh is considered low. The country has a very limited energy reserve; small amounts of oil, coal and countable natural gas reserves. The country suffers an internal energy struggle, as about 88% of the country’s power producing thermal plants are gas-based. To solve this problem, renewable energy is being used.</p>

scholarly journals Present Situation of Electrical Energy Demand, Supply, Projection of Demand-supply and Renewable Energy Utilization and Progress

2020 ◽  
Author(s):  
Md Nazmul Islam
Keyword(s):  
Renewable Energy ◽  
Energy Consumption ◽  
Energy Demand ◽  
Electrical Energy ◽  
Present Situation ◽  
Energy Utilization ◽  
Economic Activities ◽  
Power Development ◽  
Per Capita ◽  
Renewable Energy Generation

<p>A brief overview of present electricity demand, supply, projection of them and renewable energy generation and progress has been presented in this paper. Electricity is the major source of power for most of the country's economic activities. According to the Bangladesh Power Development Board in July 2018, 90 percent of the population had access to electricity. However per capita energy consumption in Bangladesh is considered low. The country has a very limited energy reserve; small amounts of oil, coal and countable natural gas reserves. The country suffers an internal energy struggle, as about 88% of the country’s power producing thermal plants are gas-based. To solve this problem, renewable energy is being used.</p>

scholarly journals Coupling simulation with artificial neural networks for the optimisation of HVAC controls in manufacturing environments

2020 ◽  
Author(s):  
Victoria Jayne Mawson ◽  
Ben Richard Hughes
Keyword(s):  
Machine Learning ◽  
Energy Consumption ◽  
Energy Demand ◽  
Large Data ◽  
Electrical Energy ◽  
Building Energy ◽  
Machine Learning Algorithms ◽  
Data Sets ◽  
Unseen Data ◽  
Manufacturing Environments

Abstract Manufacturing remains one of the most energy intensive sectors, additionally, the energy used within buildings for heating, ventilation and air conditioning (HVAC) is responsible for almost half of the UK’s energy demand. Commonly, these are analysed in isolation from one another. Use of machine learning is gaining popularity due to its ability to solve non-linear problems with large data sets and little knowledge about relationships between parameters. Such models use relationships between inputs and outputs to make further predictions on unseen data, without requiring any understanding regarding the system, making them highly suited to dealing with the stochastic data sets found in a manufacturing environment. This has been seen in literature for determining electrical energy demand for residential or commercial buildings, rather than manufacturing environments. This study proposes a novel method of coupling simulation with machine learning to predict indoor workshop conditions and building energy demand, in response to production schedules, outdoor conditions, building behaviour and use. Such predictions can subsequently allow for more efficient management of HVAC systems. Based upon predicted energy consumption, potential spikes were identified and manufacturing schedules subsequently optimised to reduce peak energy demand. Coupling simulation techniques with machine learning algorithms eliminates the requirement for costly and intrusive methods of data collection, providing a method of predicting and optimising building energy consumption in the manufacturing sector.

scholarly journals Cost-Benefit Analysis of Hybrid Photovoltaic/Thermal Collectors in a Nearly Zero-Energy Building

Energies ◽  
2019 ◽  
Vol 12 (8) ◽  
pp. 1582 ◽  
Author(s):  
Conti ◽  
Schito ◽  
Testi
Keyword(s):  
Energy Consumption ◽  
Energy Demand ◽  
Electrical Energy ◽  
Energy System ◽  
Primary Energy ◽  
Hot Water ◽  
Solar Thermal ◽  
Primary Energy Consumption ◽  
Solar Thermal Energy ◽  
Zero Energy

This paper analyzes the use of hybrid photovoltaic/thermal (PVT) collectors in nearly zero-energy buildings (NZEBs). We present a design methodology based on the dynamic simulation of the whole energy system, which includes the building energy demand, a reversible heat pump as generator, the thermal storage, the power exchange with the grid, and both thermal and electrical energy production by solar collectors. An exhaustive search of the best equipment sizing and design is performed to minimize both the total costs and the non-renewable primary energy consumption over the system lifetime. The results show that photovoltaic/thermal technology reduces the non-renewable primary energy consumption below the nearly zero-energy threshold value, assumed as 15 kWh/(m2·yr), also reducing the total costs with respect to a non-solar solution (up to 8%). As expected, several possible optimal designs exist, with an opposite trend between energy savings and total costs. In all these optimal configurations, we figure out that photovoltaic/thermal technology favors the production of electrical energy with respect to the thermal one, which mainly occurs during the summer to meet the domestic hot water requirements and lower the temperature of the collectors. Finally, we show that, for a given solar area, photovoltaic/thermal technology leads to a higher reduction of the non-renewable primary energy and to a higher production of solar thermal energy with respect to a traditional separate production employing photovoltaic (PV) modules and solar thermal (ST) collectors.

Impact of Laser-Based Technologies in the Energy-Consumption of Metal Cutters: Comparison between Commercially Available Systems

2011 ◽  
Vol 473 ◽  
pp. 809-815 ◽  
Author(s):  
Marta Oliveira ◽  
João P. Santos ◽  
Fernando G. Almeida ◽  
Ana Reis ◽  
João P. Pereira ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Electricity Consumption ◽  
Electrical Energy ◽  
Work Conditions ◽  
Design Guidelines ◽  
Machining Processes ◽  
Alternative Technologies ◽  
Similar Work ◽  
Definition Of ◽  
Process Energy

This paper introduces a framework for the Ecodesign of sheet metal cutters, which targets the definition of a set of design guidelines for this type of machine-tools, based on the contribution of the main equipment sub-systems to the processing and environmental impacts associated to their electrical energy consumption. A comparative study of commercially available Laser cutting equipments, using CO2 or doped fiber as the energy source, is described. Two parallel analysis of electricity consumption have been carried out: (1) the observation of CO2-Laser cutters usage, production modes and work conditions in real industrial environments, and (2) a comparison between these and a Fiber-Laser equipment, for a similar work order (material and thickness). The specific process energy with the different equipments was calculated, and confirms the importance of alternative technologies and practices for the energy efficiency of machining processes.

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