In manufacturing industries, metal machining is very important process due to the competitiveness. Every manufacturer needs quick, effective and optimized processes. The experience of the operator plays a major role, but even for a skilled operator it is very difficult to attain the optimum values each time. Sustainability Analysis has attracted growing interests from industry, as an optimum cost estimation system analysis method, and energy consumption progress has been achieved. In this work, scrap production as well as production lead time have to be reduced and machining cost per kg of material is target. To reduce the cost, energy consumption and material wastage impact of the milling process worldwide many aspects of the process are investigated. In the present work, a system has been proposed, which can be used to determine various components of Sustainability analysis of milling process.
The sustainability of a manufacturing process can be measured by three main factors which impact both ecological and financial constraints. These factors are the energy required to achieve a specific job, the material utilized for the job, and the time taken to complete that job. These factors have to be quantified and analysed so that a proper manufacturing system can be designed to optimize process sustainability. For this purpose, a computer package, which utilizes life cycle inventory models has been presented for CNC (Computer Numerical Control) milling and turning processes. Based on utilization of resources and production stages, the job completion time for the turning and milling processes can be divided into process (i.e., machining), idle and basic times. As parameters are different for evaluating the process times, i.e., depth and width of cut in case of milling, initial and final diameters for turning, two different case studies are presented, one for each process. The effect of material selection on the sustainability factors has been studied for different processes. Our simulations show that highly dense and hard materials take more time in finishing the job due to low cutting speed and feed rates as compared to soft materials. In addition, face milling takes longer and consumes more power as compared to peripheral milling due to more retraction time caused by over travel distance and lower vertical transverse speeds than the horizontal transverse speed used in a peripheral retraction process.
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