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.

scholarly journals Data-driven sustainability evaluation of machining system: a case study

2021 ◽  
Author(s):  
Cuixia Zhang ◽  
Cui Wang ◽  
Conghu Liu ◽  
Guang Zhu ◽  
Wenyi Li ◽  
...  
Keyword(s):  
Manufacturing Industry ◽  
Evaluation Method ◽  
Calculation Model ◽  
Machining Process ◽  
Data Driven ◽  
Energy Materials ◽  
Sustainability Evaluation ◽  
Innovative Practice ◽  
Machining System

Abstract Improving resource efficiency and reducing waste discharge are the inevitable trend of the development of sustainable machining system. Therefore, a data-driven sustainability evaluation method of machining system is proposed. The input (energy, materials, equipment, R&D and services), and output (wastes and products) data of machining system are collected. These dimensional data are processed by emergy. The emergy flow calculation model of the machining process is established for data modeling, and the sustainability evaluation index of machining system is constructed for data analysis. Finally, an engine base machining process is taken as case study for innovative practice; and the targeted process optimization is adopted based on its sustainability evaluation for innovative practice. The feasibility and effectiveness of the method are verified. This study provides theoretical and methodological support for promoting the sustainability of the manufacturing industry.

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.

Preliminary Design of Two Dimensional Vibration Assisted Machining System for Multi-Axis Micro-Milling Application

2020 ◽  
Vol 846 ◽  
pp. 105-109
Author(s):  
Gandjar Kiswanto ◽  
Poly ◽  
Yolanda Rudy Johan ◽  
Tae Jo Ko
Keyword(s):  
Machining Process ◽  
Micro Milling ◽  
Machining Processes ◽  
Machined Surface ◽  
Planar Surfaces ◽  
Preliminary Model ◽  
Machined Surface Quality ◽  
Machining System ◽  
Linear Vibrations ◽  
Linear Movement

Vibration assisted machining (VAM) is a method that is widely used in improving the performance of machined products. External vibrations with high frequency to ultrasonic range along with an meso-micrometer amplitude are given to the cutting tool or workpiece. This will result in a periodic separation phenomenon, hence reducing the cutting force which has positive impacts on increasing tool life and machined surface quality. Among the high-precision machining processes, micro-milling which has the ability to produce complex components with 2D and 3D features, can also be applied with the vibration assisted method, known as vibration assisted micro-milling (VAMM). Based on the direction of vibration given in the machining process, there are 1D VAMM with linear vibrations and 2D VAMM with circular or elliptical trajectory vibrations. However to date, neither developed 1D nor 2D VAMM systems are still limited to the research of planar surfaces cutting using linear movement axes, meanwhile vibration assisted in inclination cutting of micro-milling using the rotational movement axes is still very rare. Therefore the purpose of this paper is to present the preliminary model in designing a 2D VAMM system for a 5-axis micro-milling machine. The system is powered using piezoelectric actuators as the vibration-producing actuators.

PROCESS INDEPENDENT MACHINING SIMULATION — A BAR TURNING APPROACH

2007 ◽  
Vol 06 (01) ◽  
pp. 5-19 ◽  
Author(s):  
EYSION A. LIU ◽  
YIQING YUAN ◽  
JAMES D. HILL ◽  
QIAN ZOU
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cost Effective ◽  
High Volume ◽  
Machining Process ◽  
Machining Processes ◽  
High Volume Production ◽  
Manufacturing Productivity ◽  
Bar Turning ◽  
Force Calculation

Computer simulation of industrial processes is an important alternative that may be used either to complement or to replace expensive experimental procedures associated with developing new parts or modifying existing process. For a metal cutting process, numerical simulations provide vital information about cutting forces, cutting temperatures, tooling and part distortion, etc. Since the early 1970s, FEA has been applied to simulate machining process. The development of this approach, its assumptions and techniques has been widely accepted. Nowadays, the manufacturing productivity even drives the community to the next level innovation through computer utilizations. A kinematic simulation of machining processes is one of many innovative CAE applications, especially beneficial to high volume production of automotive powertrain parts. In this paper, a generic force calculation method is introduced with a modified horsepower correction factor. An example of sizing milling force, milling paths and proper milling parameters is provided by utilizing the methodology. This paper will also discuss and propose how the manufacturing industry uses this resourceful tool. Applications of the methodology would empower product and manufacturing engineers to make intelligent and cost effective decisions.

Experimental Analysis of Damping Fixture for Thin-Walled Workpiece Milling

2016 ◽  
Vol 836-837 ◽  
pp. 296-303
Author(s):  
Dong Sheng Liu ◽  
Ming Luo ◽  
Ding Hua Zhang
Keyword(s):  
Manufacturing Industry ◽  
Machining Process ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Machining Parameters ◽  
System Parameters ◽  
Thin Walled Structures ◽  
Machining System ◽  
Machining Test ◽  
Thin Walled

Thin-walled workpieces are widely used in the aerospace manufacturing industry in order to reduce the weight of structure and improve working efficiency. However, vibration is easy to occur in machining of thin-walled structures due to its low stiffness. Machining vibration will result in lower machining accuracy as well as machining efficiency. In order to reduce the machining vibrations of thin-wall workpieces, commonly used method is to select proper machining parameters according to the chatter stability lobes, which is generated according to the machining system parameters. However, this method requires exact system parameters to be determined, which are always changing in the machining process. In this paper, a special designed fixture with damping materials for the thin-walled workpiece is presented based on the machining vibration control theory, and analysis of the effect of vibration suppressing is obtained through the contrast of vibration tests of milling the thin-walled workpiece on the damping clamp. The damping material is used to consume vibration energy and provide support for thin-walled structure. Machining test was carried out for thin-walled structure machining to validate the effectiveness of the proposed method.

Bayesian approach to measurement scheme analysis in multistation machining systems

2003 ◽  
Vol 217 (8) ◽  
pp. 1117-1130 ◽  
Author(s):  
D Djurdjanovic ◽  
J Ni
Keyword(s):  
Bayesian Approach ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Errors ◽  
Machining System ◽  
Stream Of Variation ◽  
Linear State ◽  
Dimensional Errors ◽  
Scheme Analysis

Different measurement schemes in multistation machining systems carry different amounts of information about the root causes of dimensional machining errors. The choice of a measurement strategy in a multistation machining system is therefore crucial for subsequent successful identification of the machining error root causes. Recent advances in the linear state-space modelling of dimensional errors in multistation machining processes facilitate a formal and systematic characterization of measurement schemes. In this paper, the stream-of-variation methodology is employed to characterize various measurement schemes quantitatively in multistation machining systems using the Bayesian approach in statistics. Application of these methods is demonstrated in the characterization of measurement schemes in the machining process used for machining of an automotive cylinder head.

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.

The Development of Virtual Machining System Based on ACIS

2007 ◽  
Vol 10-12 ◽  
pp. 860-863
Author(s):  
J. Wu ◽  
Ying Xue Yao ◽  
J.G. Li
Keyword(s):  
Process Simulation ◽  
Manufacturing Industry ◽  
Machining Process ◽  
Virtual Machining ◽  
Nc Machine Tool ◽  
Machining Process Simulation ◽  
Machining System ◽  
Nc Machine ◽  
Swept Volume ◽  
High Degree

The NC machine tool is widely used in today's manufacturing industry. In this paper, a framework of the NC lathing dynamic simulation system is presented and the machining process simulation is developed based on the solid modeling method with ACIS geometric engine and 3D graphic display. The tool swept volume is designed and Boolean difference of the cutter swept volume with the raw stock in the system is calculated. The user or trainee can practice all operations, procedures and skills in complete safety, while maintaining a high degree of realism.

scholarly journals Chatter Suppression in Machining Processes

2021 ◽  
Author(s):  
Israr Ahmed Siddiqui
Keyword(s):  
Stability Boundary ◽  
Cutting Speed ◽  
Machining Process ◽  
Vibration Source ◽  
Skilled Workers ◽  
Machining Processes ◽  
Chatter Suppression ◽  
Excited Vibration ◽  
Machining System ◽  
Tool Chatter

The development of an untended machining system has been the subject of research for quite some time. Today, the need for such a system is greater thatn is once was because of the shortage of skilled workers, higher machining speeds, increase in precision machining, and the need to lower downtime. One aspect of machining process has been under investigation is tool chatter. Chatter is a machining instability resulting from self-excited vibration caused by interaction of the chip removal process, the cutting tool, and the structure of the machine tool. Chatter can severely reduce the material rate by putting limits to cutting speed and width of cut. This thesis describes a novel approach for active, on line suppresion of chatter in machining operations. The goal of chatter suppression is to minimize the chatter amplitude and therefore extend the chatter stability boundary. Once the presence of chatter is detected the suppression system will be activated. A neural network model is used to calculate current gradient values with respect to the parameters of the active vibratration source. This gradient information will be used by an optimization module to find the optimal set of parameters for the active vibration source. The methodology described is evaluated through simulation studies and simulation results confirmed the effectiveness of the approach.

Analysis and Fabrication of a Mechanical Quick-Stop for Research on Chip Formation in Hard Turning Process

2019 ◽  
Vol 889 ◽  
pp. 87-94
Author(s):  
Nguyen Thi Quoc Dung
Keyword(s):  
Chip Formation ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
On Chip

Metal cutting is one of the most important machining processes in manufacturing industry. Thorough understanding of metal cutting process facilitates the optimization in selection of cutting tools and machining parameters. There are several methods used for studying phenomena in metal cutting process. Using a quick-top device is an efficient technique for investigation cutting process in which cutting action is stopped so suddenly that the “froze” specimen called the chip root honestly depicts what happened during cutting action. Design strategies of a quick-stop are accelerating cutting tool away from the workpiece or decelerating the workpiece remaining in engagement with the tool. Operation of a quick-stop device can be either mechanically or by explosive. Quick-stop devices can be utilized for various types of machining processes such as: turning, milling, drilling. This paper described the analysis, fabrication, and testing of a quick-stop device which is used for researching on chip formation in hard turning. This device has simple and safe operation which utilizes spring forces to retract the tool from workpiece during cutting. The results of performance at cutting speed of 283 m/min show that the separation distance is quite small, less than 0.2mm so that the deformations on the root chip are close to that while actual machining process. This indicates that the device has satisfied the requirements of an equipment for studying on chip formation.

Sign in / Sign up

Export Citation Format

Share Document