Strategies to reduce energy and metalworking fluid consumption for the sustainability of turning operation: A review

Fernando, W.L.R.; Karunathilake, Hirushie; Gamage, J.R.

doi:10.1016/j.clet.2021.100100

Cited by 14 publications

(16 citation statements)

References 95 publications

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“…The minimization of energy consumption can be succeeded by the best cooling techniques, cutting parameters and innovative machining tools. 16,34 In this study, Hioki brand 9340 model device (Japan) was used to measure the total energy consumed in different machining parameters. This device is connected to the main input of the CNC machine in the layout shown in Figure 1.…”

Section: Methodsmentioning

confidence: 99%

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

Çakıroğlu

Günay

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The difficulties in machinability due to the developments in the technical properties of engineering materials increase the importance of machinability indicators such as surface quality, power or energy consumption and tool life in terms of sustainable machining. In this context, the machinability of a copper-beryllium alloy (C17500), which is used in a wide range of industries and also characterized as a hybrid material, was investigated in vortex tube cooling and dry cutting environments. First, turning experiments were performed with a coated carbide tool and varying cutting speed, feed rate and depth of cut. In the experiments, the total energy consumed during turning and the roughness of the machined surfaces were measured, and analysed experimentally and statistically. In the second stage, mathematical models were developed for the total energy consumption and average surface roughness for both cutting environments with the response surface method. As a result, the chip formation process in the turning of the Cu alloy under vortex tube cooling negatively affected the cutting power and positively contributed to the surface quality. Due to the fact that vortex tube cooling creates a cooling effect rather than lubrication, built-up layer/built-up edge (BUL/BUE) formation on the tool cutting edges caused the change in the tool geometry and thus the chip removal process became more difficult and increased the energy consumption. On the other hand, in the vortex tube cooling application, the surface roughness decreased by an average of 31.4% compared to dry cutting. Furthermore, the predictive mathematical models developed for the total energy consumption and the mean surface roughness can be used with high reliability.

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Section: Methodsmentioning

confidence: 99%

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

Çakıroğlu

Günay

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…The sustainable development of cutting techniques should focus on the high level of productivity, low processing cost, and sustainable manufacturing to reduce the resource consumption. Fernando et al (2021) underlined that the proper design of cutting tool geometry and suitable cutting parameters with the help of simulating models and parameters optimization models play a vital role in the cutting industry to realize sustainable development. Optimal parameters selection could improve section quality, extend its shelf-life, and decrease energy consumption.…”

Section: Challenges and Future Perspectivesmentioning

confidence: 99%

“…Sustainable development has received significant attention in recent years. The manufacturing industry requires massive energy to produce products that will generate a large amount of carbon dioxide (CO 2 ), which accounts for 65% of global greenhouse gases in the early century (Fernando et al., 2021). Therefore, it is important to reduce energy consumption during the cutting process.…”

Section: Challenges and Future Perspectivesmentioning

confidence: 99%

“…Fernando et al. (2021) underlined that the proper design of cutting tool geometry and suitable cutting parameters with the help of simulating models and parameters optimization models play a vital role in the cutting industry to realize sustainable development. Optimal parameters selection could improve section quality, extend its shelf‐life, and decrease energy consumption.…”

Section: Challenges and Future Perspectivesmentioning

confidence: 99%

See 1 more Smart Citation

Advanced cutting techniques for solid food: Mechanisms, applications, modeling approaches, and future perspectives

Xu¹,

Wang²,

Deng³

et al. 2022

Comp Rev Food Sci Food Safe

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Cutting is an imperative operation in the food‐manufacturing factory, separating food into a predefined geometry. A broad range of solid foods, with various components, textures, and structures, pose enormous challenges to conventional cutting strategies. Additionally, the cutting performance is significantly impacted by the processing parameters, wherein trial‐and‐error or empirical methods are often used to select the parameters in source‐wasting and time‐consuming ways. Hence, there is a need to accelerate the development of advanced cutting techniques and novel modeling approaches in the food‐manufacturing industry. Recently, advanced cutting techniques (ultrasonic vibration‐assisted [UVA], laser, and waterjet cutting) are seen to be superior in processing foods of various textures, with the advantages of high cutting quality, low contamination, and easy operation. Compared with conventional cutting, advanced cutting techniques can dramatically reduce cutting force and energy consumption, resulting in high efficiency, energy‐and‐source saving, and low carbon footprint. Additionally, the finite element (FE) model does simulate the cutting process well, and artificial intelligence (AI) technology is competent to optimize the cutting parameters. This review is perhaps the first one focusing on the advanced cutting techniques applied in the food industry, serving as a summary of the cutting mechanisms, critical influence factors, and applications of conventional and advanced cutting techniques including UVA, laser, and waterjet cutting. In addition, the modeling approaches with respect to FE and AI models are emphasized. Finally, the challenges and future perspectives of advanced cutting techniques combined with modeling approaches are highlighted, and those approaches are promising in the future intelligent food‐manufacturing industry. Practical Application The review clearly demonstrates that advanced cutting techniques as having advantages such as high efficiency, energy‐and‐source saving, and low damages, thus exhibiting great potential in processing food of various textures with high cutting quality, low contamination, and easy operation. Additionally, the FE model does simulate the cutting process well and AI is competent in optimizing the cutting parameters, which possesses great potential in providing comprehensive cutting information and selecting the optimal combination of cutting parameters.

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“…The machining sector is considered a major consumer of energy. High energy consumption increases the emission of harmful gases like carbon dioxide, and sulfur dioxide [1]. The emission of these gases has a hazardous effect on human beings and the surrounding environment since they are considered greenhouse gases.…”

Section: Introductionmentioning

confidence: 99%

A review of cooling and lubrication techniques for machining difficult-to-cut material.

Ashmawy

Elsheikh²,

El-Kassas³

2023

Journal of Engineering Research

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Superalloys have magnificent properties which make them widely applied in various industrial fields. They possess high mechanical properties such as high strength, high rupture resistance, and high resistance to corrosion and oxidation. Since they can maintain these properties even at elevated temperatures, they face some problems during the cutting and machining process. They are classified as difficult-to-cut alloys, which means that high heat is generated in the cutting zone due to their poor thermal conductivity. In addition, high friction takes place between the tool and the chip. To overcome these problems during their machining process, different cooling and lubrication techniques using suitable cutting fluids are highly recommended. In this study, the cooling and lubrication techniques that have been applied in the literature to machine superalloys such as dry machining, flood cooling, high-pressure jet machining, minimum quantity lubrication and cooling, and cryogenic machining are reviewed. The technique of each type followed by its advantages and disadvantages are mentioned.

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Strategies to reduce energy and metalworking fluid consumption for the sustainability of turning operation: A review

Cited by 14 publications

References 95 publications

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

Advanced cutting techniques for solid food: Mechanisms, applications, modeling approaches, and future perspectives

A review of cooling and lubrication techniques for machining difficult-to-cut material.

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