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Journal articles on the topic 'Energy-efficient machining'

Author: Grafiati

Published: 6 September 2023

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1

Peng, Tao, and Xun Xu. "Energy-efficient machining systems: a critical review." International Journal of Advanced Manufacturing Technology 72, no. 9-12 (June 2014): 1389–406. http://dx.doi.org/10.1007/s00170-014-5756-0.

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2

Denkena, Berend, Patrick Helmecke, and Lars Hülsemeyer. "Energy efficient machining of Ti–6Al–4V." CIRP Annals 64, no. 1 (2015): 61–64. http://dx.doi.org/10.1016/j.cirp.2015.04.056.

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3

Newman, S. T., A. Nassehi, R. Imani-Asrai, and V. Dhokia. "Energy efficient process planning for CNC machining." CIRP Journal of Manufacturing Science and Technology 5, no. 2 (January 2012): 127–36. http://dx.doi.org/10.1016/j.cirpj.2012.03.007.

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4

Liu, Dawei, Wei Wang, and Lihui Wang. "Energy-Efficient Cutting Parameters Determination for NC Machining with Specified Machining Accuracy." Procedia CIRP 61 (2017): 523–28. http://dx.doi.org/10.1016/j.procir.2016.11.215.

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5

Bliedtner, Jens, Thomas Schmidt, Hartmut Müller, and Sabine Sändig. "Energy-efficient Laser Machining of Siliceous Strand Profiles." Laser Technik Journal 11, no. 5 (November 2014): 42–45. http://dx.doi.org/10.1002/latj.201400051.

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6

Kausar, Zareena, Muhammad Faizan Shah, Zeeshan Masood, Hafiz Zia Ur Rehman, Sardor Khaydarov, Muhammad Tallal Saeed, Omid Razmkhah, and Haseeb Yaqoob. "Energy Efficient Parallel Configuration Based Six Degree of Freedom Machining Bed." Energies 14, no. 9 (May 5, 2021): 2642. http://dx.doi.org/10.3390/en14092642.

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The process of material removal from a workpiece to obtain the desired shape is termed machining. Present-day material removal technologies have high spindle speeds and thus allow quick material removal. These high-speed spindles are highly exposed to vibrations and, as a result, the accuracy of the final workpiece’s dimensions is compromised. To overcome this problem, the motion of the tool is restricted, and multiple degrees of freedom are given through the motion of the workpiece in different axes. A machining bed configured as a parallel manipulator capable of giving six degrees of freedom (DOF) to the workpiece is proposed in this regard. However, the proposed six DOF machining bed should be energy efficient to avoid an increase in machining cost. The benefit of using the proposed configuration is a reduction in dimensional error and computational time which, as a result, reduces the energy utilization, vibrations, and machining time in practice. This paper presents kinematics, dynamics and energy efficiency models, and the development of the proposed configuration of the machining bed. The energy efficiency model is derived from the dynamics model. The models are verified in simulation and experimentally. To minimize error and computation time, a PID controller is also designed and tested in simulation as well as experimentally. The resulting energy efficiency is also analyzed. The results verify the efficacy of the proposed configuration of the machining bed, minimizing position error to 2% and reducing computation time by 27%, hence reducing the energy consumption and enhancing the energy efficiency by 60%.

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Cai, Wei, Li Li, Shun Jia, Conghu Liu, Jun Xie, and Luoke Hu. "Task-Oriented Energy Benchmark of Machining Systems for Energy-Efficient Production." International Journal of Precision Engineering and Manufacturing-Green Technology 7, no. 1 (July 19, 2019): 205–18. http://dx.doi.org/10.1007/s40684-019-00137-x.

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8

Denkena, Berend, Patrick Helmecke, and Lars Hülsemeyer. "Energy Efficient Machining with Optimized Coolant Lubrication Flow Rates." Procedia CIRP 24 (2014): 25–31. http://dx.doi.org/10.1016/j.procir.2014.07.140.

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9

Uhlmann, Eckart, Sascha Reinkober, and Tobias Hollerbach. "Energy Efficient Usage of Industrial Robots for Machining Processes." Procedia CIRP 48 (2016): 206–11. http://dx.doi.org/10.1016/j.procir.2016.03.241.

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10

Deiab, Ibrahim. "On Energy Efficient and Sustainable Machining through Hybrid Processes." Materials and Manufacturing Processes 29, no. 11-12 (October 7, 2014): 1338–45. http://dx.doi.org/10.1080/10426914.2014.921706.

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11

Fujishima, Makoto, Masahiko Mori, and Yohei Oda. "Energy-efficient manufacturing on machine tools by machining process improvement." Production Engineering 8, no. 1-2 (August 25, 2013): 217–24. http://dx.doi.org/10.1007/s11740-013-0492-0.

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12

Wang, Honghui, Ray Y. Zhong, Guijie Liu, WeiLei Mu, Xiaojie Tian, and Dingxin Leng. "An optimization model for energy-efficient machining for sustainable production." Journal of Cleaner Production 232 (September 2019): 1121–33. http://dx.doi.org/10.1016/j.jclepro.2019.05.271.

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13

Oda, Yohei, Makoto Fujishima, and Yoshimi Takeuchi. "Energy-Saving Machining of Multi-Functional Machine Tools." International Journal of Automation Technology 9, no. 2 (March 5, 2015): 135–42. http://dx.doi.org/10.20965/ijat.2015.p0135.

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The purpose of the study described in this paper was to develop an energy-saving strategy for machining of multi-functional machine tools by pairing various turning and milling processes with various cutting conditions. The amounts of electric energy consumed during turning, facing, end milling, and drilling were measured and analyzed. Based on the experimental results, the most efficient machining processes and methods for reducing electric energy were identified. It was found to be important to employ severe cutting conditions as much as possible and to reduce the electric energy associated with machining of multi-functional machine tools during standby periods.

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14

Neugebauer, Reimund, Carsten Hochmuth, Gerhard Schmidt, and Martin Dix. "Energy Efficient Process Planning Based on Numerical Simulations." Advanced Materials Research 223 (April 2011): 212–21. http://dx.doi.org/10.4028/www.scientific.net/amr.223.212.

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The main goal of energy-efficient manufacturing is to generate products with maximum value-added at minimum energy consumption. To this end, in metal cutting processes, it is necessary to reduce the specific cutting energy while, at the same time, precision requirements have to be ensured. Precision is critical in metal cutting processes because they often constitute the final stages of metalworking chains. This paper presents a method for the planning of energy-efficient machining processes based on numerical simulations. It encompasses two levels of planning flexibility: process adjustment and process design. At the process adjustment level, within the constraints of existing machines and tools, numerical simulations of orthogonal cutting are used to determine cutting parameters for increased energy efficiency. In this case, the model encompasses specific cutting energy, tool wear, chip geometry, and burr shape. These factors determine the energy and resources required for the chip formation itself, tool replacements, cleaning and deburring and with that the overall energy efficiency and precision. In the context of process design, with the ability to select machines, machine configurations, tools, and cooling systems, numerical simulations of cutting processes that incorporate machine and tool conditions are applied in the planning of energy-efficient machining. The method is demonstrated for the case of drilling processes and supported by experimental investigations that identify the main influences on energy efficiency in drilling.

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15

Seidel, B., C. Heinzel, D. Meyer, P. Geilert, and B. Karpuschewski. "Sustainable machining by energy- and resource-efficient application of metalworking fluids." Procedia Manufacturing 43 (2020): 151–58. http://dx.doi.org/10.1016/j.promfg.2020.02.129.

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16

Li, X. X., W. D. Li, and F. Z. He. "A multi-granularity NC program optimization approach for energy efficient machining." Advances in Engineering Software 115 (January 2018): 75–86. http://dx.doi.org/10.1016/j.advengsoft.2017.08.014.

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17

Serin, Gokberk, Murat Ozbayoglu, and Hakki Ozgur Unver. "Integrated energy-efficient machining of rotary impellers and multi-objective optimization." Materials and Manufacturing Processes 35, no. 4 (April 30, 2019): 478–90. http://dx.doi.org/10.1080/10426914.2019.1605177.

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18

Liang, Y. C., X. Lu, W. D. Li, and S. Wang. "Cyber Physical System and Big Data enabled energy efficient machining optimisation." Journal of Cleaner Production 187 (June 2018): 46–62. http://dx.doi.org/10.1016/j.jclepro.2018.03.149.

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19

Wang, Lihui, Wei Wang, and Dawei Liu. "Dynamic feature based adaptive process planning for energy-efficient NC machining." CIRP Annals 66, no. 1 (2017): 441–44. http://dx.doi.org/10.1016/j.cirp.2017.04.015.

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20

Xia, Tangbin, Xiangxin An, Huaqiang Yang, Yimin Jiang, Yuhui Xu, Meimei Zheng, and Ershun Pan. "Efficient Energy Use in Manufacturing Systems—Modeling, Assessment, and Management Strategy." Energies 16, no. 3 (January 19, 2023): 1095. http://dx.doi.org/10.3390/en16031095.

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Currently, studies on the energy efficiency of manufacturing systems usually lack synthetic and systematic techniques. In this paper, a holistic framework is demonstrated in order to achieve more sustainable manufacturing, which covers machine-level, system-level and life-cycle-level energy efficiency techniques. Based on these, the mechanism of how energy consumption is affected by machining processes and system operation is analyzed to achieve a comprehensive decision on energy efficiency optimization. Four main topics are included in this paper: (1) Hierarchical sustainability goals and metrics for energy-efficient manufacturing; (2) Machine-level machining processes optimization for energy efficiency enhancement; (3) System-level innovations for efficient consumption management; (4) Life-cycle level energy flow modeling and energy recycling strategy. An automotive engine manufacturing system is taken as an example to build a concrete understanding of the application of the framework. Moreover, this holistic framework establishes the theoretical basis for promoting the energy efficiency of automotive engine manufacturing systems. Furthermore, the proposed techniques can provide decision-making support for achieving sustainable manufacturing in a wider scope of mechanical manufacturing.

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21

Zhang, Chaoyang, and Pingyu Jiang. "Sustainability Evaluation of Process Planning for Single CNC Machine Tool under the Consideration of Energy-Efficient Control Strategies Using Random Forests." Sustainability 11, no. 11 (May 30, 2019): 3060. http://dx.doi.org/10.3390/su11113060.

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As an important part of industrialized society, manufacturing consumes a large amount of raw materials and energy, which motivates decision-makers to tackle this problem in different manners. Process planning is an important optimization method to realize the object, and energy consumption, carbon emission, or sustainability evaluation is the basis for the optimization stage. Although the evaluation research has drawn a great deal of attention, most of it neglects the influence of state control of machine tools on the energy consumption of machining processes. To address the above issue, a sustainability evaluation method of process planning for single computer numerical control (CNC) machine tool considering energy-efficient control strategies has been developed. First, four energy-efficient control strategies of CNC machine tools are constructed to reduce their energy consumption. Second, a bi-level energy-efficient decision-making mechanism using random forests is established to select appropriate control strategies for different occasions. Then, three indicators are adopted to evaluate the sustainability of process planning under the consideration of energy-efficient control strategies, i.e., energy consumption, relative delay time, and machining costs. Finally, a pedestal part machined by a 3-axis vertical milling machine tool is used to verify the proposed methods. The results show that the reduction in energy consumption considering energy-efficient control strategies reaches 25%.

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22

Karpov, A. V. "Towards Energy Intensity Reduction of Machining Fabrication Procedures." Applied Mechanics and Materials 756 (April 2015): 111–15. http://dx.doi.org/10.4028/www.scientific.net/amm.756.111.

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The article is devoted to the rational consumption of energy resources when processing of blanks of machine component parts with metal-cutting tools during machine-building production. The scientific and methodological approach to the establishment of energy-efficient processing conditions is proposed, the one is based on the optimization of fabrication procedures according to new energy efficiency criterion. It was given the study of advantages and disadvantages of known methods of fabrication procedures optimization according to the criterion of the lowest specific energy intensity. New integral indicator of energy efficiency of cutting operation is formulated as a ratio of constructional material specific energy intensity to the specific energy consumption in the cutting area. The methods of determining of energy efficiency figure with taking into account the properties of processed material, the behaviors of its deformation and fracture, type of formed chippings and technological purpose of processing are offered. Optimization of machining fabrication procedures with usage of new criterion permits reduction of energy costs in the cutting area by 18-22% in comparison with applicable processing conditions.

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23

Shin, S.-J. "A hybrid process planning for energy-efficient machining: Application of predictive analytics." IOP Conference Series: Materials Science and Engineering 635 (October 28, 2019): 012032. http://dx.doi.org/10.1088/1757-899x/635/1/012032.

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24

Wang, Zhigang, Shogo Nakashima, and Mark Larson. "Energy Efficient Machining of Titanium Alloys by Controlling Cutting Temperature and Vibration." Procedia CIRP 17 (2014): 523–28. http://dx.doi.org/10.1016/j.procir.2014.01.134.

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25

Zhao, Guoyong, Yu Su, Guangming Zheng, Yugang Zhao, and Chunxiao Li. "Tool tip cutting specific energy prediction model and the influence of machining parameters and tool wear in milling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 10 (April 13, 2020): 1346–54. http://dx.doi.org/10.1177/0954405420911298.

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Most of the existing energy-consumption models of machine tools are related to specific machine components and hence cannot be applied to other machine tools with different specifications. In order to help operators optimize machining parameters for improving energy efficiency, the tool tip cutting specific energy prediction model based on machining parameters and tool wear in milling is developed, which is independent of the standby power of machine tools and the spindle no-load power. Then, the prediction accuracy of the proposed model is verified with dry milling AISI 1045 steel experiments. Finally, the influence of machining parameters and tool wear on tool tip cutting specific energy is studied. The developed model is independent of machine components, so it can reveal the influence of machining parameters and tool wear on tool tip cutting specific energy. The tool tip cutting specific energy reduces with the increase in the cutting depth, side cutting depth, feed rate, and cutting speed, while increases linearly as the tool wears gradually. The research results are helpful to formulate efficient and energy-saving processing schemes on various milling machines.

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26

Meng, Yue, Li Hui Wang, Xue Feng Wu, Xian Li Liu, and Guang Xu Ren. "A Study on Energy Consumption of a CNC Milling Machine Based on Cutting Force Model." Materials Science Forum 800-801 (July 2014): 782–87. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.782.

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Machining operations are performed by machine tools with a large amount of energy consumed for material removal. Understanding and characterizing the energy consumption is essential to explore the potential of energy-saving in energy-efficient machining. For this purpose, this paper proposes a method for modeling energy consumption of end milling operation which is based on cutting theory. The cutting power model is verified with experiments on a CNC milling machine. According to the calculated and experimental results, it is clear that the theoretical prediction can predict the mean cutting power successfully as validated by actual measurements.

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27

Shrivastava, Pankaj Kumar, Shrihar Pandey, and Shivam Dangi. "Electrical arc machining: Process capabilities and current research trends." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 15 (May 1, 2019): 5190–200. http://dx.doi.org/10.1177/0954406219846151.

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Electrical arc machining is the thermal energy-based unconventional machining process, which utilizes energy of arc to melt and vaporize workpiece material. Electrical arc machining has the capability to machine advanced materials such as metal matrix composites, superalloys, and conductive ceramics effectively. The process is considered to be efficient than most of the other unconventional machining processes in terms of the material removal rate. But it has got limitations because it results in a very poor surface finish. Tool wear rate, recast layer formation, surface and subsurface cracks, and geometrical inaccuracy are other limitations up to a certain extent. In this paper, the comprehensive review of research carried out so for in the area of electrical arc machining has been presented. The paper discusses the detailed experimental and theoretical studies done on electrical arc machining to elucidate the effects of various input control factors on different quality characteristics. The paper also contains modeling and optimization studies done so far in electrical arc machining and finally discusses the future research possibilities in the area.

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28

Wang, Honghui, Xun Xu, Chengrui Zhang, and Tianliang Hu. "A hybrid approach to energy-efficient machining for milled components via STEP-NC." International Journal of Computer Integrated Manufacturing 31, no. 4-5 (May 8, 2017): 442–56. http://dx.doi.org/10.1080/0951192x.2017.1322220.

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29

Denkena, Berend, Benjamin Bergmann, and Björn-Holger Rahner. "Energy-efficient control of dust extraction for the machining of fibre-reinforced plastics." Procedia CIRP 78 (2018): 49–54. http://dx.doi.org/10.1016/j.procir.2018.08.178.

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30

Samukawa, Tetsuo, and Haruhiko Suwa. "An Optimization of Energy-Efficiency in Machining Manufacturing Systems Based on a Framework of Multi-Mode RCPSP." International Journal of Automation Technology 10, no. 6 (November 4, 2016): 985–92. http://dx.doi.org/10.20965/ijat.2016.p0985.

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It has become important to consider energy-efficient optimization not only in a process design but also in the operations of manufacturing systems to promote sustainable and green manufacturing. This paper extends authors’ previous work to a more practical situation to demonstrate the applicability of the proposed framework of energy-efficient manufacturing operations based on a resource-constrained project scheduling problem (RCPSP). Both have varying resource requirements and multi processing modes, which can produce a suitable energy-load profiles for complete manufacturing systems. This study proposes a mathematical model for producing optimal energy-load profiles, and based on these profiles, each given operation is allocated to a machine tool with a specific processing mode. A processing mode refers to machining conditions for the corresponding operation, conditions that provide a predictive processing time and estimated electrical energy consumption. Through some cutting experiments on aluminum alloy performed on a three-axis machining center, we provide several possible processing modes for workpieces (operations), and we generate energy-load profiles by applying multi start local searches. We then discuss the applicability and capability of the energy-load profiles as an energy-aware production control.

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31

Farooqi, Awais, and Nukman bin Yusoff. "Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review." Applied Mechanics and Materials 899 (June 2020): 135–43. http://dx.doi.org/10.4028/www.scientific.net/amm.899.135.

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Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

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32

Maximov, Yury. "Theory and Practice of Technology for Machining Non-Rigid Smooth Shafts." Key Engineering Materials 496 (December 2011): 168–75. http://dx.doi.org/10.4028/www.scientific.net/kem.496.168.

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In modern machine-building the problem of creating highly-efficient technological mechanical machining processes, taking into account the energy and resources-saving and ecological requirements is one of the paramount importance. Throughout the whole period of machine-building technology development there were great difficulties owing to the problems of machining parts with low rigidity and high demands on quality. At creating the technological processes of similar parts’ machining, as at creating any technological process, it is necessary to provide realization of the principle of combining technical, economic and organization assignments. But unlike usual technological processes, in this case it is much more difficult to meet all these requirements.

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33

Shumyacher, Vyacheslav M., Sergey A. Kryukov, and Natal'ya V. Baidakova. "Methodology for Evaluation of Treated Steels and Alloys in Abrasive Processing." Defect and Diffusion Forum 410 (August 17, 2021): 262–68. http://dx.doi.org/10.4028/www.scientific.net/ddf.410.262.

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One of the critical physical and mechanical properties of metals and alloys is the suitability for abrasive machining. Machining by abrasive tools is the final operation that sets the desired macro-geometry parameters of processed blanks and microgeometry parameters of processed surfaces such as roughness and length of a bearing surface. Abrasive machining determines the most important physical and mechanical parameters of a blank surface layer, i.e. stresses, phase composition, structure. Machinability by abrasive tools depends on the machining performance affected both by the blank material properties and various processing factors. In our previous studies, we proved that during abrasive machining the metal microvolume affected by abrasive grains accumulates energy. This energy is used for metal dispersion and is converted into heat. According to the theoretical studies described herein, one may note the absence of a reliable and scientifically valid method as well as measuring instruments to determine the machinability of metals and alloys by abrasive tools. For this reason, we suggested a method simulating the effect the multiple abrasive grains produce in a grinding wheel, and enabling us to identify machinability of metals and alloys, select the most efficient abrasive materials for machining of the same, and form the basis for development of effective grinding operations.

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34

Ali Khan, Muhammad, Syed Husain Imran Jaffery, Mushtaq Khan, Muhammad Younas, Shahid Ikramullah Butt, Riaz Ahmad, and Salman Sagheer Warsi. "Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions." Mechanical Sciences 10, no. 2 (December 4, 2019): 561–73. http://dx.doi.org/10.5194/ms-10-561-2019.

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Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

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35

Vuong, Ngoc-Dung, Renjun Li, Chee-Meng Chew, Amir Jafari, and Joseph Polden. "A novel variable stiffness mechanism with linear spring characteristic for machining operations." Robotica 35, no. 7 (June 9, 2016): 1627–37. http://dx.doi.org/10.1017/s0263574716000357.

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SUMMARYVariable stiffness mechanisms are able to mechanically reconfigure themselves in order to adjust their system stiffness. It is generally accepted that only antagonistic designs, featuring quadratic springs, can produce linear spring-like behaviour (i.e., a linear relationship between the displacement and its resultant force). However, these antagonistic designs typically are not as energy efficient as series-based designs. In this work, we propose a novel variable stiffness mechanism that can achieve both linear-spring behaviour whilst maintaining an energy efficient characteristic. This paper will present the working principle, mechanical design and characterization of the joints stiffness properties (verified via experimental procedure). The pros and cons of this novel design with reference to the other Variable Stiffness Actuator (VSA) designs will be discussed based on experimental results and in the context of general machining tasks.

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36

Xiao, Yongmao, Jincheng Zhou, Ruping Wang, Xiaoyong Zhu, and Hao Zhang. "Energy-Saving and Efficient Equipment Selection for Machining Process Based on Business Compass Model." Processes 10, no. 9 (September 13, 2022): 1846. http://dx.doi.org/10.3390/pr10091846.

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The optimal selection of machine equipment can reduce the energy consumption and processing time of the parts processing process in enterprises. The energy consumption and time of using different equipment to process the same product vary greatly. Traditional equipment selection is only through qualitative analysis comparing the process characteristics of using different equipment or optimizing parameters for a single piece of equipment. It does not take into account the dynamics of the production process and does not consider the impact of process factors on production decisions. To solve this problem, we established a production equipment selection model based on the business compass model and proposed a calculation method that considered energy consumption and time objectives in the production process. Quantitative analysis can be performed for different equipment. The energy consumption and processing time of different equipment are calculated by the beetle antennae search (BAS) algorithm. A case study of machining end cap holes was carried out. The results showed that this method can calculate the optimal energy consumption and the optimal time of different equipment for producing the same product, which has good theoretical and practical significance for enterprises and governments to choose energy-saving and efficient production equipment.

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37

Zhou, Zongjie, Kai Liu, Jianping Zhou, Yan Xu, and Lizhong Wang. "A highly energy-efficient milling of Inconel 718 via modulated short electric arc machining." Journal of Manufacturing Processes 78 (June 2022): 46–58. http://dx.doi.org/10.1016/j.jmapro.2022.03.051.

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38

Wei, Zhenzhen, Wenzhu Liao, and Liuyang Zhang. "Hybrid energy-efficient scheduling measures for flexible job-shop problem with variable machining speeds." Expert Systems with Applications 197 (July 2022): 116785. http://dx.doi.org/10.1016/j.eswa.2022.116785.

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39

Li, X. X., F. Z. He, and W. D. Li. "A cloud-terminal-based cyber-physical system architecture for energy efficient machining process optimization." Journal of Ambient Intelligence and Humanized Computing 10, no. 3 (May 10, 2018): 1049–64. http://dx.doi.org/10.1007/s12652-018-0832-1.

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40

Tebni, Wissem, M. Boujelbene, and E. Bayraktar. "Parametric Approach Model for Determining Electrical Discharge Machining (EDM) Conditions: Effect of Cutting Parameters on the Surface Integrity." Advanced Materials Research 83-86 (December 2009): 725–37. http://dx.doi.org/10.4028/www.scientific.net/amr.83-86.725.

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Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. There are various types of products which can be produced by using the EDM such as dies and moulds. Today many parts used in aerospace and automotive industry and also final processes of surgical components can be finished by EDM process. A simple and easily understandable model was proposed for predicting the relative importance of different factors (composition of the steels and Electro Discharge Machining processing conditions) in order to obtain an efficient pieces. A detail application on the tool steels machined by EDM was given in this study. This model is based on thermal, metallurgical and mechanical and also in situ test conditions. It gives detail information on the effect of electrochemical parameters on the surface integrity and sub-surface damage of the material (Heat Affected Zone, HAZ), the level of residual stresses, and the surface texture. This approach is an efficient way to separate the responsibilities of the steel maker and machining process designer for increasing the reliability of the machined structures.

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41

Singaravel, Balasubramaniyan, and Thangiah Selvaraj. "Experimental Investigation on Cutting Forces, Specific Cutting Pressure, Co-Efficient of Friction and Shear Energy in Turning of HSLA Steel." Management and Production Engineering Review 7, no. 1 (March 1, 2016): 71–76. http://dx.doi.org/10.1515/mper-2016-0008.

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Abstract Machinability study of a material is used to find the ease and difficulty during machining operation. High Strength Low Alloy (HSLA) medium carbon steel (EN25 steel) is considered to possess better mechanical properties than carbon steel. In this work, an attempt is made to experimentally investigate and realize the machinability of EN25 steel during turning with coated carbide tools. The effects of machining parameters on cutting force components, Specific Cutting Pressure (SCP), co-efficient of friction and shear energy are analysed during the investigation. The results of the investigation revealed that the mentioned machinability characteristics are necessary and essential to evaluate the machinability of HSLA steel effectively.

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He, Shanshan, Daojiang Ou, Changya Yan, and Chen-Han Lee. "A chord error conforming tool path B-spline fitting method for NC machining based on energy minimization and LSPIA." Journal of Computational Design and Engineering 2, no. 4 (June 12, 2015): 218–32. http://dx.doi.org/10.1016/j.jcde.2015.06.002.

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Abstract Piecewise linear (G01-based) tool paths generated by CAM systems lack G1 and G2 continuity. The discontinuity causes vibration and unnecessary hesitation during machining. To ensure efficient high-speed machining, a method to improve the continuity of the tool paths is required, such as B-spline fitting that approximates G01 paths with B-spline curves. Conventional B-spline fitting approaches cannot be directly used for tool path B-spline fitting, because they have shortages such as numerical instability, lack of chord error constraint, and lack of assurance of a usable result. Progressive and Iterative Approximation for Least Squares (LSPIA) is an efficient method for data fitting that solves the numerical instability problem. However, it does not consider chord errors and needs more work to ensure ironclad results for commercial applications. In this paper, we use LSPIA method incorporating Energy term (ELSPIA) to avoid the numerical instability, and lower chord errors by using stretching energy term. We implement several algorithm improvements, including (1) an improved technique for initial control point determination over Dominant Point Method, (2) an algorithm that updates foot point parameters as needed, (3) analysis of the degrees of freedom of control points to insert new control points only when needed, (4) chord error refinement using a similar ELSPIA method with the above enhancements. The proposed approach can generate a shape-preserving B-spline curve. Experiments with data analysis and machining tests are presented for verification of quality and efficiency. Comparisons with other known solutions are included to evaluate the worthiness of the proposed solution. Highlights The presented B-spline tool path fitting method is chord-error conforming. It is numerically stable and hence industrial-strength. The proposed ELSPIA algorithm incorporates stretching energy into LSPIA algorithm. Includes actual machining experiments to validate the worthiness.

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Hu, Chen, and Yongwei Zhu. "System Design and Mechanism Study of Ultrasonic-Assisted Electrochemical Grinding for Hard and Tough Materials." Processes 11, no. 6 (June 7, 2023): 1743. http://dx.doi.org/10.3390/pr11061743.

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In this study, an ultrasonic-assisted electrochemical grinding (UAECG) system was designed to improve the low efficiency and tool wear in conventional grinding of hard and tough materials. In this system, multiple-field energy consisting of ultrasonic, electrochemical and mechanical grinding was used. The processing mechanism was investigated to determine the interaction mechanism between ultrasonic, grinding and electrochemical processing. The established theoretical model showed that the processing efficiency was affected by the ultrasonic amplitude, ultrasonic frequency, electrolyte conductivity and other parameters. In verifying the feasibility of UAECG machining and the effect of machining elements on machining, a series of corresponding machining experiments was conducted. Experiments showed that the machining efficiency can be improved by machining through the UAECG system. The material removal rate of W18Cr4V machining was 2.7 times higher than that of conventional grinding and 1.7 times higher than UAG. The processing efficiency of YT15 was increased by 3.2 times when the processing voltage increased from 2 to 6 V. The surface shape and roughness were also affected by these parameters. The surface roughness of the SiCp/Al workpiece reached the best level at 4 V as the machining voltage increased from 2 to 6 V. However, the surface roughness increased significantly when the voltage increased to 6 V. Thus, parameters such as machining voltage must be optimised for efficient and precise machining in practice.

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Gao, Yicong, Shanghua Mi, Hao Zheng, Qirui Wang, and Zhe Wei. "An Energy Efficiency Tool Path Optimization Method Using a Discrete Energy Consumption Path Model." Machines 10, no. 5 (May 8, 2022): 348. http://dx.doi.org/10.3390/machines10050348.

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As the energy cost accounts for about one-third of the total manufacturing cost, there is great significance in evaluating and managing energy consumption in manufacturing processes. The energy consumption during multi-axis end milling, which represents a large part of the industrial energy costs, is usually extraordinarily large, especially for complex free-form surfaces requiring multi-finish-machining. To obtain the most efficient tool path, the tool orientation is adjusted to obtain the largest cutting stripe width at each cutter contact point. However, the use of excessive driving energy consumption and cutting energy to obtain the largest cutting stripe width may reduce the energy efficiency of the tool path. To solve this problem, the geometry features of the tool path are analyzed firstly, and the global energy consumption analysis, which includes a cutting energy analysis and driving energy analysis, is conducted. The discrete energy consumption path model is constructed to find the most energy-efficient tool orientation sequence for a tool path. Finally, contrast experiments are carried out to validate the proposed method.

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Abdul Hadi, Muaaz, Markus Brillinger, Marcel Wuwer, Johannes Schmid, Stefan Trabesinger, Markus Jäger, and Franz Haas. "Sustainable peak power smoothing and energy-efficient machining process thorough analysis of high-frequency data." Journal of Cleaner Production 318 (October 2021): 128548. http://dx.doi.org/10.1016/j.jclepro.2021.128548.

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Duan, Molong, and Chinedum E. Okwudire. "Energy-Efficient Controller Design for a Redundantly Actuated Hybrid Feed Drive With Application to Machining." IEEE/ASME Transactions on Mechatronics 21, no. 4 (August 2016): 1822–34. http://dx.doi.org/10.1109/tmech.2015.2500165.

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Ogawa, Tsuyoshi. "Building of Efficient, Energy-Saving Lines with an Extremely-Compact Machining Center and CNC Lathe." International Journal of Automation Technology 4, no. 2 (March 5, 2010): 150–54. http://dx.doi.org/10.20965/ijat.2010.p0150.

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Industrial products today are expected to be smaller, lighter, and more multi-functioned, and such products consist of numbers of extremely small and precise components. Yet, turnovers of such products are short, and their production volumes fluctuate at extreme. The production engineering for such components, however, which should correspond to, and optimized for this situation is still in progress, even though such components are growing in numbers and kinds: becoming even smaller in size and the demand fluctuates more. We have developed extremely compact machining center and CNC lathe, which covers these points: most optimum means of production for small or microscopic components. We have also built a concept of a production system, today commonly called “desktop factory” by using multiple numbers of these “desktop” machines.

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Kozak, J., K. P. Rajurkar, and S. Z. Wang. "Material Removal in WEDM of PCD Blanks." Journal of Engineering for Industry 116, no. 3 (August 1, 1994): 363–69. http://dx.doi.org/10.1115/1.2901953.

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Polycrystalline diamond (PCD) tools are now widely used in machining a large variety of advanced materials. However, the manufacture of PCD tool blanks is not an economical and efficient process. The shaping of PCD blanks with conventional machining methods (such as grinding), is a long, labor-intensive and costly process. Wire electric discharge machining (WEDM) promises to be an effective and economical technique for the production of tools from PCD blanks. However, a knowledge base for wire electrical discharge machining of PCD blanks needs comprehensive investigations into the proper parameter setting, metal removal mechanisms, and surface integrity of machined blanks. This paper presents the results of experimental and theoretical investigations of the influence of discharge frequency and discharge energy on the material removal rate of WEDM of PCD blanks. The mechanism of removing diamond grains from the matrix during electrical erosion is also discussed on the basis of thermal stresses between the diamond grain and cobalt phase.

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Hashish, M. "Comparative Evaluation of Abrasive Liquid Jet Machining Systems." Journal of Engineering for Industry 115, no. 1 (February 1, 1993): 44–50. http://dx.doi.org/10.1115/1.2901637.

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This paper presents a comparison between two types of abrasive liquid jet cutting systems: entrainment systems, which typically use abrasive-waterjets (AWJs) to perform the cutting; and systems that use directly pumped abrasive slurry jets (ASJs) to perform the cutting. The hardware features and the performance characteristics of the two types of systems are addressed. A simplified analysis indicates that at an abrasive-to-liquid ratio of 1:1, high-pressure directly pumped ASJs are twice as efficient as entrainment AWJs in transferring energy to the particles. Also, directly pumped ASJs are potentially over 20 times as dense with regard to kinetic power delivery to the workpiece. However, high-pressure entrainment AWJs can be more effective than low-pressure directly pumped ASJs.

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Muhammad, Riaz, Naseer Ahmed, Anish Roy, and Vadim V. Silberschmidt. "Turning of Advanced Alloys with Vibrating Cutting Tool." Solid State Phenomena 188 (May 2012): 277–84. http://dx.doi.org/10.4028/www.scientific.net/ssp.188.277.

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A demand for high-strength alloys in aerospace, marine and off-shore industries has stimulated development of new and efficient machining techniques. In the recent past, a novel machining technique known as ultrasonically assisted turning (UAT) has been introduced; in it low-energy ultrasonic vibration is superimposed on movement of a cutting tool. In the present work, a comparative study of machining of two advanced alloys - Ti15V3Cr3Al3Sn and Inconel 718 - is carried out numerically by developing a two-dimensional finite-element model of the turning process. A non-linear material description is used in the FE model to incorporate plastic deformation behaviour of the high-strength alloys. The model is employed to investigate the effect of tool geometry and contact conditions on cutting forces, temperature of the cutting region and the chip shape in orthogonal turning of modern alloys.

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