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

Abstract

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.

Machine Learning-Based Prediction of Specific Energy Consumption for Cut-Off Grinding

“…The detailed procedure for energy consumption and the corresponding cutting power measurement is elaborated in the previous work [ 5 ].…”

“…At point D, energy consumption usually stabilizes. The average value of the energy consumed during this stabilization stage is used to measure the energy consumption [ 5 , 31 ]. However, in this particular case, it can be seen that energy did not stabilize for the whole time period between D and G. It stabilizes in two stages, at E and F, and the average values of the energy consumed at both of these points were used for evaluation purposes.…”

“…Understanding and estimation are primary and important steps to reduce the energy consumption of machining [ 4 ]. Specific energy consumption (SEC), i.e., the energy required to remove the unit volume of the material, is an important indicator to understand and analyze the energy consumption pattern among different materials [ 5 ]. The abrasive cut-off operation, which is the thin sectioning of the metals with cutting discs, is a high-material-removal-rate grinding process and consumes a lot of energy [ 6 , 7 ].…”

“…The specific energy of grinding and its associated components are highly influenced by the process parameters [ 8 ]. Numerous experimental and modeling techniques have been directed to model and evaluate grinding energy and its components [ 5 , 9 , 10 , 11 ]. However, these techniques rely on complex mathematical formulations to find the relationship between the grinding energy and the process parameters and are based on specific assumptions, which might vary during the experimental conditions.…”

“…Unlike the comprehensive studies of machine learning-based energy prediction of machining and surface grinding, none of the efforts have been directed towards machine learning or data-driven-based prediction of specific energy consumption for cut-off grinding, which is the widely used finishing operation in the industry. The recently conducted and previous studies about the abrasive cut-off operation for metals, stone machining, and concrete rely on the complex modeling of specific energy consumption in relationship with the process parameters [ 5 , 22 , 23 , 24 , 25 ]. These models are true under certain assumptions and for specific conditions and might not represent an accurate estimation of energy during data variation due to practical constraints.…”