Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding

Alberro, Amelia Nápoles; Rojas, Hernan Alberto González; Egea, Antonio J. Sánchez; Hameed, Shafqat; Aguilar, Reyna Mercedes Peña

doi:10.3390/ma12060939

Cited by 15 publications

(9 citation statements)

References 32 publications

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“…10. The reduction of plowing energy with the material removal rate is in agreement with previous research on grinding [6,14]. The sliding power depends on the rotational speed of the cutting disc.…”

Section: Cutting Modelsupporting

confidence: 90%

“…High-energy deep grinding and cut-off operations take place predominantly in the material removal regime through a chip formation for ductile materials or through a crack formation for brittle materials. Nápoles et al [14] developed a material removal rate model to evaluate the specific energy consumption during industrial-scale grinding of C45K with different thermal treatments and AISI 304. It was demonstrated that the sliding energy was the main form of energy dissipation and decreased with an increase in the depth of the cut.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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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.

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Section: Cutting Modelsupporting

confidence: 90%

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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“…However, the introduction of this technology for the manufacture of components is faced with a number of difficulties. Grinding energy efficiency depends on the appropriate selection of cutting conditions, grinding wheel, workpiece material, and lubrication conditions [15,16]. There are difficulties with obtaining a repeatable result as it is difficult to achieve the assumed depth of hardening and to obtain the assumed hardness after grinding, which results in the necessity of applying the so-called softening grinding.…”

Section: Figurementioning

confidence: 99%

The Influence of the Depth of Cut in Single-Pass Grinding on the Microstructure and Properties of the C45 Steel Surface Layer

et al. 2020

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The paper contains the results of a metallographic examination and nanoindentation test conducted for the medium carbon structural steel with low content of Mn, Si, Cu, Cr, and Ni after its grinding to a depth ranging from 2 μm to 20 μm, at constant cutting speed (peripheral speed) of vs = 25 ms−1 and constant feed rate of vft = 1 m/min. Applied grinding parameters did not cause the surface layer hardening, which could generate an unfavorable stress distribution. The increase in the surface hardness was obtained due to the work hardening effect. Microstructure, phase composition, and chemical composition of the grinded surface layer were examined using an X-ray diffractometer, light microscope, and scanning microscope equipped with X-ray energy-dispersive spectroscopy, respectively. Hardness on the grinded surface and on the cross-section was also determined. It was shown that the grinding of C45 steel causes work hardening of its surface layer without phase transformation. What is more, only grinding to a depth of 20 μm caused the formation of an oxide scale on the work-hardened surface layer. Nanoindentation test on the cross-section, at a short distance from the grinded surface, has shown that ferrite grains were more susceptible to work hardening than pearlite grains due to the creation of an equiaxed cellular microstructure, and that different dislocation substructure was created in the work-hardened surface layer after grinding to different depths.

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“…Researchers developed different models to analyse the dominance of particular energy component. For instance, Napoles et al [50] developed the material removal rate model to evaluate specific energy consumption during industrial scale grinding of C45K with different thermal treatments and AISI 304. They demonstrated that sliding energy is the main form of energy dissipation, and it decreases with increase of depth of cut.…”

Section: Dominance Of Specific Energy Components In Grinding Processesmentioning

confidence: 99%

“…The adopted model demonstrated the statistical accuracy to evaluate the specific energy consumption(SEC) with respect to material removal rate for the processes of grinding, milling, turning and injection moulding [64]. Recently, Napoles et al [50] adopted the same model for surface grinding to analyse the three energy components during industrial scale surface grinding.…”

Section: 3 Model Of Specific Energy Consumptionmentioning

confidence: 99%

Specific energy consumption of metal cutting with thin abrasive discs

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The aim of this research is to provide an in-depth understanding of energy consumption in abrasive disc cutting processes. The specific energy consumed in cutting is measured,analysed, and then characterised in to three components. To this end, an experimental device is built using an Arduino-controlled grinder to measure the specific energy consumed by cutting at different feed rates. Using a model, the experimental data is validated and the Specific Energy Consumed is separated into three energy components: sliding, ploughing and specific cutting energy. Furthermore, the influence of cutting conditions and material properties significantly influenced the specific energy consumption and its components. To analyse the effect of grain shape and the relative dependence of the different components of the Specific Energy Consumed as a function of material removal rate, integral models of specific ploughing energy, specific sliding energy and specific cutting energy are developed. Conventional and super abrasive cubitron abrasive grains were used. Cutting with pyramidal abrasive discs (cubitron) was used for the determination of the relative components of the specific energy consumed. It was found that the specific ploughing energy is more sensitive to the change in material removal rate compared to the sliding energy. Due to the fast shearing and precisely shaped cubitron grains, the transition from sliding to a specific shear regime was so fast for some materials that the magnitude of the ploughing energy was found to be negligible.However, the model implementation for some materials showed that the absence or presence of ploughing energy also depends on the rate of material removed. Finally, the development of a cutting grain model is presented which will allow the study of the chip compression ratio which is not possible to characterise by means of a single cutting grain in metal cutting with thin abrasive discs. This latest development is the beginning of a study of chip formation in the primary cutting zone of an abrasive grain. This research provides a machine and a methodology to characterise cutting with commercially available abrasive discs in terms of the Specific Energy Consumed parameter. El objetivo de esta investigación es proporcionar un conocimiento profundo sobre el consumo de energía en los procesos de corte con discos abrasivos. Se mide y analiza la energía específica consumida en el corte, caracterizando dicha energía en tres componentes. Para ello se construye un dispositivo experimental que utiliza una amoladora controlada por un Arduino, para medir la energía específica consumida por el corte a diferentes velocidades de alimentación. Utilizando un modelo, se validaron los datos experimentales y se separa la Energía Específica Consumida en tres componentes energéticos: deslizamiento, arado y energía de corte específica. Además, la influencia de las condiciones de corte y las propiedades del material influyeron significativamente en el consumo de energía específico y sus componentes. Para analizar el efecto de la forma del grano y la dependencia relativa de las diferentes componentes de la Energía Específica Consumida en función de la tasa de remoción de material. Se desarrollan modelos integrales de energía de arado específica, energía de deslizamiento específica y energía de corte específica. Se utilizaron granos abrasivos convencionales y súper abrasivos de Cubitrón. El corte con discos abrasivos de granos piramidales (cubitron) se utilizaron para la determinación de las componentes relativas de la energía específica consumida. Se encontró que la energía de arado específica es más sensible al cambio en la tasa de remoción de material en comparación con la energía de deslizamiento. Debido a los granos de Cubitrón de corte rápido y de forma precisa, la transición de deslizamiento a un régimen de corte específico fue tan rápida para algunos materiales que la magnitud de la energía de arado resultó ser insignificante. Sin embargo, la implementación del modelo para algunos materiales demostró que la ausencia o presencia de energía de arado también depende de la tasa de material removido. Por último se presenta el desarrollo de un modelo de grano de corte que permitirá estudiar la relación de compresión de la viruta que no es posible caracterizar a través de un solo grano de corte en el corte de metales mediante discos abrasivos delgados. Este último desarrollo es el comienzo de un estudio de la formación de viruta en la zona primaria de corte de un grano abrasivo. Esta investigación proporciona una máquina y una metodología para caracterizar el corte con disco abrasivos, disponibles comercialmente, en términos del parámetro Energía Específica Consumida.

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Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding

Cited by 15 publications

References 32 publications

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

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

The Influence of the Depth of Cut in Single-Pass Grinding on the Microstructure and Properties of the C45 Steel Surface Layer

Specific energy consumption of metal cutting with thin abrasive discs

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