Reducing the Energy Consumption of Circular Saws in the Cutting Process of Plywood

Cutting, as the most widely used machining process, is applied in both primary and secondary wood processing. Optimum cutting conditions that result in the high quality of the machined surface and low energy consumption are crucial for wood processing. The effects of the feed speed, cutting speed and average chip thickness on the energy consumption and surface temperature of a circular saw blade during the cutting process of two types of plywood with a thickness of h = 14 mm is described in this paper. In experimental measurements, two circular saw blades with cutting tungsten carbide inserts for wood were used as tools. One circular saw blade was standard, and was not surface treated (CSB1), and second circular saw blade (CSB2) differed by the powder coating surface and the length of the cutting edge. In the experiment, the energy consumption and the surface temperature of the circular saw blade was measured in order to find the optimal cutting conditions for the most energy-efficient cutting process. The results show that the cutting power and the surface temperature of the circular saw blade increased when the feed speed increased. The investigated values of the surface-treated circular saw blade were lower compared to the values of the standard circular saw blade. When comparing the lightweight plywood with the classic plywood, experimentally obtained cutting power values of the circular saw were made 19% lower on average by using the circular saw blade CSB1. When using the CSB2 circular saw blade, these values of the cutting power of the circular saw were 22% lower on average. The surface temperature of the circular saw blade is the highest on the outer edge (tooth root area 31.7 °C) and decreases towards the center of the circular saw blade. There must be a reasonable compromise between machine productivity and energy consumption.

CUTTING STONE BUILDING MATERIALS WITH CUT WHEELS OF CUBIC BORON NITRIDE

The advantage of cutting stone building materials with SSM (synthetic superhard materials) wheels is that, first of all, it is possible to obtain high processing productivity and dimensional stability, which are 3..5 and 50…100 times higher than those of traditional tools based on carborundum, respectively. The study of the process of cutting stone materials with CBN (cubic boron nitrite) wheels is aimed at establishing force dependences, determining the cutting power and heating temperature of the cutting disc during operation. The forces were measured using a tensometric dynamometer UDM-50. To measure and calculate the cutting temperature, a thermoelectric method based on the formation of practically not inertial microthermocouples during cutting was used. The temperature to which the CBN cutting wheel on a metal base is heated is a limiting factor in processing, since when heated to a temperature of 600ºС, the strength of the wheel decreases by half, which can cause its rupture under the action of centrifugal forces, as well as loss of stability and jamming during cutting. In the present study, the wheel temperature was measured after one minute of continuous operation. The values of the component of the cutting force PY, depending on the processing modes, can reach values of the order of 70 N. The values of the component of the cutting force PZ, depending on the processing modes, can reach values of 45 N. The cutting power can be 2800W. The temperature resistance of the wheel (heating time of the wheel up to 600ºС) when cutting dry is maximum 28 minutes, when grinding with cooling of the cutting zone with negative temperature air from a Ranque-Hilsch tube, the temperature resistance is 35 minutes, with ejector cooling of sprayed coolant 37 minutes and with jet-pressure cooling it is 40 minutes. The maximum cutting length is respectively 0.7: 0.8; 0.9 and 2m. The cutting power is 600...2800W.

Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

Ti-6Al-4V ELI (Grade 23) is highly recommended for bio-materials and due to its low thermal conductivity and chemically reactive properties, machinability is poor. Thus the current work emphasized on the selection of appropriate cooling technique and optimal cutting parameters for machining of Ti-6Al-4V ELI alloy with sustainability analysis for surface roughness, flank wear and cutting power. Initially, the cutting performances under dry, flood and MQL environments are compared and MQL is observed to better performed. At lower speed (70 m/min), MQL exhibited 26.38% and 19.69% lesser surface roughness relative to dry and flood cooling individually. At the same cutting condition, MQL assisted cutting resulted in lower flank wear relative to dry (157. 33%) and flood cooling (40%). Further, a detailed investigation has been made under MQL through Taguchi L18 design of experiments. The major mechanisms for flank wear are found to be abrasion, chipping and notch wear. Optimal data set through Grey relational analysis is found to be v1 (70 m/min), f1 (0.1 mm/rev) and d1 (0.1 mm) and improved. Quadratic regression model is found to be significant for prediction of responses. Sustainability Pugh matrix assessment revealed that MQL environment enhanced the economical, technological as well as environmental and operator health aspects. Reduction of energy consumption by 53.96% and savings of carbon footprints by 68.46 kg of CO2 observed under MQL at optimal conditions and thus saves manufacturing cost.

Power Consumption Analysis and Experimental Study on the Kneading and Cutting Process of Licorice Stem in Horizontal Total Mixed Ration Mixer

Aiming at the problems of high-power consumption and insufficient kneading and cutting of roughage in the total mixed ration mixer. In this paper, licorice stems were taken as experimental objects, the horizontal twin-shaft TMR mixer was used to carry out the experimental study. It should be as brief as possible and concise. Through the kneading and cutting process power analysis, determine the influencing factors of kneading and cutting power consumption. The auger speed, processing time and blade type were taken as experimental factors, with standard straw length rate and power consumption as indicators, Box–Behnken test with three factors and three levels was carried out, analysis of variance was performed on the test results, the results show that the significant effect of each factor on the standard grass length is processing time, blade type and auger speed in descending order. The significance of the influence on power consumption from large to small is auger speed, processing time and blade type. The response surface analysis and parameter optimization were carried out, the results show that the auger speed is 20 r/min, the processing time is 29 min, and the blade type is quincunx blade. At this time, the standard straw length was 82.634%; Power consumption 4525.815 kJ, TMR mixer performance reached the best. The results can provide a theoretical basis for the subsequent research and development of TMR mixer.

An investigation on cutting sound effect on power consumption and surface roughness in CBN tool-assisted hard turning

In machining activities, sound emission is one of the key factors toward the operator's health and safety. Sound generation during cutting is the outcome of the interaction between tool and work. The intensity of sound greatly influences the cutting power consumption and surface finish obtained during machining. Therefore, the current work emphasized the analysis of sound emission, power consumption, and surface roughness in hard turning of AISI 4340 steel using a CBN tool which was rarely found in the literature. Response surface methodology (RSM) and artificial neural network (ANN) techniques were utilized to formulate the model for each response. The results indicated that the maximum value of input parameters exhibited the highest level of sound due to the creation of vibration in the machine and tool. Higher sound level indicates the generation of lower power consumption but at the same instant surface roughness was leading with increment in sound level. The feed rate exhibited the utmost noteworthy consequence on surface quality with 87.71% contribution. The cutting power can be decreased by choosing the high level of cutting parameters. The RSM and ANN have a good correlation with experimental data, but the accuracy of the ANN is better than the RSM.

The force required for the creation of wood cuttings

Wood as a material has its own peculiar role during processing due to its characteristics which depend on a number of factors. Therefore, wood-based plate materials tend to encounter the same issues. The creation of the continuous cuttings is conditioned by the strength as it is being cut orthogonally. The cutting force is shown as the sum of the forces for plastic deformation, the force for overcoming the work of the friction force on the front and rear surface of the tool and the force for creating a new surface. Each of the forces is connected to appropriate mechanical features of wood. Examining the mechanical properties of wood, which can be used to calculate the required power to create a new surface, demonstrates the dependence of cutting power on the type of wood, cutting speed, and wood moisture.

DEVELOPMENT AND EVALUATION OF FINGER WHEEL AND CUTTING DISC COMBINED DEVICE FOR STALK RETURNING

Stalk returning technology was an important way to preserve soil nutrients and reduce soil erosion. It was of great significance to improve the stalk chopping quality, reduce power consumption. On the basis of the previous research, the finger wheel and cutting disc combined device for stalk returning was developed, mainly composed of the sawtooth blade group, the finger wheel and the stalk lifting grid. The stalk was fed into the cutting area of the sawtooth blades by the rotation of the finger wheel, and the operation of the stalk chopping was completed under the combination of the sawtooth blade group and the finger wheel. The movement of stalks in the device with finger wheel and sawtooth blades was analysed by high speed photography, and the rotational speed of finger wheel, the rotational speed of sawtooth blade group, the stalk feeding speed had a great influence on the movement of the stalks. Through orthogonal test and verification test, the clamping angle was 20°, the rotational speed of sawtooth blade group was 800 min-1, the stalk feeding speed was 1.45 m/s, the rotational speed of finger wheel was 110 min-1, the cut length qualified rate was 92.47% and the cutting power was 529.97 W. The test results met the quality requirements of the Chinese national standard. The related research can provide reference for the research of stalk returning device.

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

Specific energy consumption is an important indicator for a better understanding of the machinability of materials. The present study aims to estimate the specific energy consumption for abrasive metal cutting with ultra-thin discs at comparatively low and medium feed rates. Using an experimental technique, the cutting power was measured at four predefined feed rates for S235JR, intermetallic Fe-Al(40%), and C45K with different thermal treatments. The variation in the specific energy consumption with the material removal rate was analyzed through an empirical model, which enabled us to distinguish three phenomena of energy dissipation during material removal. The thermal treatment and mechanical properties of materials have a significant impact on the energy consumption pattern, its corresponding components, and cutting power. Ductile materials consume more specific cutting energy than brittle materials. The specific cutting energy is the minimum energy required to remove the material, and plowing energy is found to be the most significant phenomenon of energy dissipation.

Experience of High-Density Polyethylene as a Binding Substance in Grinding Wheels

The possibility and efficiency of the use of high-density polyethylene as a binding substance in grinding wheels for cutting-off, as well as for finish cylindrical grinding, is researched. It is determined that: - breaking mechanical strength of such circles ensures their safe operation at maximum operating speeds of 30–35 m/sec; - the use of high-density polyethylene as a binding substance in cutting wheels is not advisable, due to intensive wear and low cutting power of these tools; - wheels for finish cylindrical grinding on the basis of high-density polyethylene and hollow spherocorundum as abrasive grains in a number of key indicators (cutting power, roughness of machined surfaces) are highly competitive with grinding wheels on a bakelite bond or are comparable to them, and significantly exceed the latter in terms of wear resistance.

Impact of cutting speed and feed rate for cross cutting with saw chains

This article examined the impact of cutting speed and feed rate on the process of cross cutting with a saw chain. Three cutting speeds and three feed rates were chosen, and their impact on energy intensity was evaluated. The measurements were performed on an experimental device, on which it is possible to set the rpm (cutting speed) and the feed rate into the section using frequency converters. The cutting speed influences the resulting energy efficiency, at a cutting speed (vc) of 5.02 m × s-1 the resulting power (P) was 485 W. With increasing speed the cutting power increased, where the maximum value of P was 619 W at a cutting speed of 6.81 m × s-1. At a feed rate of 0.286 m × min-1 the cutting power was 376 W, with increasing cutting speed the cutting power (P) also increased almost linearly up to the value of 695 W at a feed rate (vf) of 0.857 m × min-1. The results showed that the cutting speed and the feed rate have a clear influence on the process of cross sawing with a saw chain.