Experimental Research of Energy Consumption of Austenitizing Heat-Treated Casting Fittings in Pipe Threading

Abstract

Energy consumption is an important part of the production cost of mass production industrial enterprises. The casting, heat treatment and threading processes involved in the industrial production of fittings result in high energy consumption. In serial production, the threading of pipe fittings is carried out using high torque and low speed. The thin-walled designs of the fittings lead to rapid cooling, causing the formation of a high rate of pearlite microstructures and subsequent low or extremely hard machinability. Heat treatment with long austenitizing time in the furnace reduces the pearlite ratio, thus enabling a ferritic microstructure to be obtained. In this study, the ½-inch BSP threading process was applied to materials having both microstructures after casting and heat treatment. As in the mass production pipe threading process, fittings were threaded in a multi-threading process using a universal lathe and in a single threading process using a CNC mill. The Power Index (PI) was measured during the metal removal process and the energy consumption of the products was calculated via energy/power conversion equations. In addition, a new model was proposed that takes into consideration the energy consumption per product (ECPP) in the mass production machining process. As a result of combining the energy consumption and energy-power transformation theory with an experimental investigation, 39% optimization was achieved. That's a result of this experimental study resulted in energy savings of 8755 kWh annually.

Finite Element‐Based Simulation of Cooling Rate on the Material Properties of an Automobile Silent Block

“…e results obtained are similar to those of studies in the literature [11][12][13][14][15]. It was observed that the hardness values increased by 25% on average by rapid cooling of the AA 6063 alloy after extrusion.…”

“…e air-cooled samples have grain sizes of 150-165 μm, whereas the grains of the watercooled ones are 18-25 μm. is was a result of the cooling rate differences because when the cooling rate is slow, it leads to slow nucleation and large grain size [13,14,27]. Consequently, cooling with water can result in a particle size six times smaller than that can be obtained with air cooling.…”

“…ese alloys are classified as the AA 6000 series. Alloys in this series are known for their good extrudability, good corrosion resistance, good weldability, and moderate strength, as well as for their low cost [13][14][15][16][17][18]. Alloys of the 6000 series make up 80% of extruded products, and 70% of these alloys are AA 6063 [19,20].…”

“…Powder metallurgy production costs are very high. Although the casting method's cost is cheap, the mechanical properties are much lower than desired [13,14]. Extrusion method is the most ideal method for this geometry according to injection.…”

Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy

“…In order for statistical analyses to be considered reliable, error values must be below 20% [28,29]. Many important studies have been carried out on energy consumption during the machining process [30][31][32][33]. e comparison of surface roughness and energy consumption values (Table 8) underscores the fact that the level of difference between the results of the confirmation test and those obtained via the Taguchi method was insignificant.…”