In the present study, the machinability indices of surface grinding of AISI D2 steel under dry, flood cooling, and minimum quantity lubrication (MQL) conditions are compared. The comparison was confined within three responses, namely, the surface quality, surface temperature, and normal force. For deeper insight, the surface topography of MQL-assisted ground surface was analyzed too. Furthermore, the statistical analysis of variance (ANOVA) was employed to extract the major influencing factors on the above-mentioned responses. Apart from this, the multi-objective optimization by Grey–Taguchi method was performed to suggest the best parameter settings for system-wide optimal performance. The central composite experimental design plan was adopted to orient the inputs wherein the inclusion of MQL flow rate as an input adds addition novelty to this study. The mathematical models were formulated using Response Surface Methodology (RSM). It was found that the developed models are statistically significant, with optimum conditions of depth of cut of 15 µm, table speed of 3 m/min, cutting speed 25 m/min, and MQL flow rate 250 mL/h. It was also found that MQL outperformed the dry as well as wet condition in surface grinding due to its effective penetration ability and improved heat dissipation property.
This paper substantiates why it is necessary to limit the dynamic loads in stand shafts when closing angular gaps. The paper is a feasibility study of a concept developed specifically to limit each of the factors that affect amplitude of the dynamic torque; limitations applied are determined on a case-by-case basis. The research team studied the components of elastic torque in a dual-mass electromechanical system of Mill 5000 caused by vibrations arising from the elasticity of transmission as well as from the vibrations caused by elastic collision itself. It is shown that the lowest possible pre-acceleration is necessary for decreasing the dynamic coefficient at a near-nominal load torque. A principle of limiting dynamic loads when closing an angular gap is proposed, which implies collecting tachograms of an electric drive subjected to positive or negative acceleration before and after the fed metal is captured. The research team has developed drive control principles to implement this approach. The recommendation is to upgrade the electric drives of the reversing stand in Mill 5000.
AC regenerative electric drives (AC REDs) are widely used in metallurgical rolling due to their reliability, efficiency, and power sufficient to maintain the process. This paper reviews the latest achievements in building the grid connection circuits for the main AC REDs of rolling mills. The paper discusses multipulse connection circuits formed by various transformer types and algorithms for preprogrammed pulse-width modulation with selective harmonic elimination technique (PPWM with SHE) of three-level active front ends (AFE), provides the theoretical and practical measurement results, and gives recommendations for improving existing systems. For 6-, 12-, and 18-pulse grid connection circuits, switching patterns of AFE semiconductor modules with a smooth downward trend within the modulation index range from 0.7 to 1.15 are provided. A simulation was performed under comparable conditions on simulation models in the Matlab/Simulink to objectively evaluate the performance and opportunities of 6-, 12-, and 18-pulse grid connection circuits, including the three-level AFE and transformer specifications. The waveforms and spectra of the grid currents and transformer secondary winding phase currents are shown; total harmonic distortion (THD) factors have been calculated up to the 60th harmonic for various PPWM with SHE patterns. The results of simulation and experimental measurement on operating equipment have been compared. The paper is expected to provide a broad overview of multipulse connection circuits of the rolling mill’s main AC REDs, in particular, identify the latest solutions capable of significantly improving their electromagnetic compatibility with the grid. The results obtained are of high genericity and can be used by researchers and engineers to provide the electromagnetic compatibility of non-linear consumers in similar circuits, as well as design them.
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