Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

Pervaiz, Salman; Kannan, Sathish; Deiab, Ibrahim; Kishawy, Hossam A.

doi:10.1177/0954405419875344

Cited by 22 publications

(11 citation statements)

References 77 publications

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“…21,40 With the influence of high-speed machining of hard-to-cut materials, the heat generation will increase and accordingly results in decrease of plastic deformation and significantly decreasing the friction due to increment of temperature. 41 The cutting fluid applied along the flank face takes away the high heat generation and accordingly increases lubrication effect at the rake face of the cutting tool. 42 Li et al 20 observed that with the increase in electrostatic voltage (20 kV), the tool life is reduced.…”

Section: Resultsmentioning

confidence: 99%

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Gunda¹,

Narala

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys are considered as hard-to-cut material due to its relatively high resistance to corrosion, low thermal conductivity and high chemical reactivity. Effective penetration of sufficient amount of lubricant in the metalworking process is of utmost importance to (a) reduce frictional resistance at the high-temperature tool–workpiece interface and (b) avert the formation of built-up edge in machining process. Traditionally, the lubricant forms a thin fluid film to reduce the friction. In order to reduce or eliminate coolant usage and to apply lubri-coolant efficiently at tool–chip–workpiece interface, a novel near-dry machining technique called electrostatic charged solid lubricant spray system has been developed. In electrostatic charged solid lubricant spray technique, the aerosolized micro-droplet particles were sprayed from the nozzle tip which uses a phenomenon called contact-charge electrification principle. The quick penetration and wettability of charged atomized droplet particles are impinged with high velocity at the tool–chip interface. The focus of the present experimental research is to analyse the optimum lubrication process parameters of the experimental set-up in terms of effectively applying cutting fluid in the machining zone. The study shows that the desired atomization and machining performance of the electrostatic charged solid lubricant spray technique can be obtained by governing different spray parameters (lubricant flow rate, air pressure, spray nozzle position, nozzle distance, electrostatic voltage). The results revealed that when the charged lubricants are applied with high velocity and large number of droplets, it will have significant influence on surface roughness and cutting force. The fabricated electrostatic charged solid lubricant spray technique provides us with an efficient and economic machining solution by applying solid lubricants effectively at tool–material interface during turning of Ti-6Al-4V alloy material. The present approach and the obtained results will help in better understanding of the machinability of hard-to-cut materials in manufacturing industries.

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Section: Resultsmentioning

confidence: 99%

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Gunda¹,

Narala

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Narciso et al provided a literature review of methods reported in the scientific literature to investigate the potential value of industrial data using machine learning tools to achieve the objectives related to energy efficiency [ 26 ]. Pervaiz et al focused on the role of energy consumption and then examined the influence of cutting tools, part materials and lubrication on the sustainability of the machining process [ 27 ]. The authors stated that the machining process sustainability can be enhanced by integrating different innovative approaches related to energy and material consumption of tools and parts.…”

Section: Preceding Review Studiesmentioning

confidence: 99%

Optimization techniques for energy efficiency in machining processes—a review

abdelaoui

Jabri

Barkany

2023

Int J Adv Manuf Technol

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Metal working process is one of the main activities in mechanical manufacturing industry; it is considered as a major consumer of energy and natural resources. In material removal process, the selection of cutting parameters and cooling or cutting liquid is necessary to save energy and achieve energy efficiency as well as sustainability. During the last two decades, the number of publications in this field has rapidly increased and has shown the importance of this research area. This review paper identifies and reviews in detail a total of 166 scientific studies which exhibit original contributions to the field and address multiple energy efficiency challenges. The recently developed models of energy consumption and different materials used in the machining process are presented. Therefore, this study describes various techniques for modeling and optimizing machining operations such as turning, milling, and drilling. Modeling techniques, experimental methods, multi-objective and single-objective optimization methods, and hybrid techniques optimization are presented in a detailed manner compared to previous review papers where only energy models are discussed. It can help practitioners and researchers to select the most appropriate approach for the desired experience and to highlight the progress of these methods in terms of machining energy efficiency. Additionally, this paper provides a review of different cutting fluids adopted in machining processes. This paper assists researchers and manufacturers in making advantageous technical decisions that have substantial economics in terms of energy saving.

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“…where: k and e-the number of parameters considered and approximate error; b i , b ii , and b ij -the regression coefficients. The total specific energy (SEC) is defined as the ratio of the total energy consumption to the material removal volume and computed as 27,28 :…”

Section: Optimization Targetsmentioning

confidence: 99%

Multi-response optimization of the actively driven rotary turning for energy efficiency, carbon emissions, and machining quality

Nguyen

Duong

Mia

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Boosting energy efficiency and machining quality are prominent solutions to achieve sustainable production for turning operations. In this work, a machining condition-based optimization has been performed to decrease the total specific energy (SEC), carbon emission (CE), and average roughness (AR) of the actively driven rotary turning (ADRT) process. The processing factors are the tool rotational speed (Tv), depth of cut (a), feed rate (fr), and workpiece speed (Wv). The turning experiments of the mold material labeled SKD11 have been conducted on a CNC lathe. The regression method is employed to develop comprehensive models of the total specific energy, carbon emissions, and average roughness. The entropy approach is then applied to drive out the weight value of each ADRT response. Finally, the non-dominated sorting particle swarm optimization (NSPSO) is utilized to determine the optimal parameters. The findings indicated that the optimal values of the Tv, a, fr, and Wv are 77 m/min, 0.32 mm, 0.25 mm/rev., and 128 m/min, respectively. The SEC, AR, and CE are decreased by 18.07%, 10.46%, and 5.02%, respectively, as compared to the initial approach. Moreover, the developed active rotary turning operation can be considered as an effective technical solution to boost the machining efficiency of hardened steels.

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Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

Cited by 22 publications

References 77 publications

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Optimization techniques for energy efficiency in machining processes—a review

Multi-response optimization of the actively driven rotary turning for energy efficiency, carbon emissions, and machining quality

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