Extended model for selection of optimum turning conditions based on minimum energy considerations

Alswat, Haitham M.; Mativenga, Paul

doi:10.1177/0954405420937558

Cited by 6 publications

(5 citation statements)

References 18 publications

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“…1 Therefore, energy conservation in manufacturing has become a critical issue and must be addressed to improve economic benefits and minimise environmental impacts. 2,3…”

Section: Introductionmentioning

confidence: 99%

“…1 Therefore, energy conservation in manufacturing has become a critical issue and must be addressed to improve economic benefits and minimise environmental impacts. 2,3 Laser processing has become an increasingly indispensable part of competitive manufacturing throughout the world. 4 In particular, laser welding has attracted considerable attention in the automotive, aerospace, nuclear, medicine and petrochemical industries.…”

Section: Introductionmentioning

confidence: 99%

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Process parameter selection for laser welding of aluminium alloy from the perspective of energy effectiveness

Xiong

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Laser welding is an indispensable part of competitive manufacturing, but it has a critical issue with energy consumption. The existing literature is limited to the energy supplied to the laser-material interaction for the material welding, and the welding quality is not well considered for energy saving. To reduce the total energy consumption of laser welding without compromising the welding quality, this study investigates the effects of process parameters including the laser power, welding speed and focus position on the specific energy consumption (SEC), welding quality and related energy effectiveness (EE) of the laser welding of 6061 aluminium alloy. The results reveal that adjusting the laser power to improve the welding quality will inevitably lead to a significant increase in the SEC. Energy can be saved with a relatively stable welding quality by varying the welding speed, and the welding quality can be improved without appreciably increasing the energy consumption by setting the focus position to approximately −0.5 mm. The EE can be enhanced with a higher laser power within a moderate welding speed range at the negative focus position. A case demonstrated that with a reasonable process parameter configuration, an energy savings of 12.45% could be realised for laser welding, while the tensile strength was increased by 4.29%, and the weld bead integrity remained stable (a decrease of 0.11%).

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“…1 Therefore, energy conservation in manufacturing has become a critical issue and must be addressed to improve economic benefits and minimise environmental impacts. 2,3…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Process parameter selection for laser welding of aluminium alloy from the perspective of energy effectiveness

Xiong

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…To decrease environmental impacts and obtain sustainable manufacturing, the energy consumed and carbon emissions should be minimized for the rotary turning operation. 21,22 The empirical models of the average roughness, turning forces, and cutting temperature for various ADRT processes have been proposed in the previous publications. Unfortunately, the comprehensive models of the total specific energy and carbon emission have not been developed.…”

Section: Introductionmentioning

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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“…The impacts of the blunt and edge of the micro-textured tool on the MF and MT in the milling titanium alloy have been explored by Tong et al (2020) [11], in which the optimal geometric characteristic was selected using the support vector regression and genetic algorithm; and the authors stated that the enhancements in the tool life (TL) and SR were 33% and 26%, respectively with the aid of the optimal micro-textured tool. Alswat et al (2020) proposed a new energy model to identify optimal values for machining parameters of turning operations, taking into account the energy footprint, the cutting tool utilization and the material removed volume [12], in which a case study was employed to validate the effectiveness of the proposed approach; and the results showed that the proposed model was effectively applied to generate reliable machining parameters, as compared to traditional ones.…”

Section: Introductionmentioning

confidence: 99%

“…The authors stated that the enhancements in the tool life (TL) and SR were 33% and 26%, respectively with the aid of the optimal micro-textured tool. Alswat and Mativenga 12 proposed a new energy model to identify optimal values for machining parameters of turning operations, taking into account the energy footprint, the cutting tool utilization and the material removed volume, in which a case study was employed to validate the effectiveness of the proposed approach. The results showed that the proposed model was effectively applied to generate reliable machining parameters, as compared to traditional ones.…”

Section: Introductionmentioning

confidence: 99%

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Nguyen

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The burnishing process is used to enhance the machining quality via improving the surface finish, surface hardness, wear-resistance, fatigue, and corrosion resistance, and it is mostly used in aerospace, biomedical, and automotive industries to improve reliability and performance of the component. The combined turning and burnishing process is therefore considered as an effective solution to enhance both machining quality and productivity. However, the trade-off analysis between energy consumption, surface characteristics, and production costs has not been well-addressed and investigated. This study presents an optimization of the compressed air assisted-turning-burnishing (CATB) process for aluminum alloy 6061, aimed to decrease the energy consumption as well as surface roughness and to enhance the Vicker hardness of the machined surface. The machining parameters for consideration include the machining speed, feed rate, depth of cut, burnishing force, and the ball diameter. The improved Kriging models were used to construct the relations between machining parameters and the technological response characteristics of the machined surface. The optimal machining parameters were obtained utilizing the desirability approach. The energy based-cost model was developed to assess the effectiveness of the proposed CATB process. The findings showed that the selected optimal outcomes of the depth of cut, burnishing force, diameter, feed rate, and machining speed are 0.66 mm, 196.3 N, 8.0 mm, 0.112 mm/rev, and 110.0 m/min, respectively. The energy consumption and surface roughness are decreased by 20.15% and 65.38%, respectively, while the surface hardness is improved by 30.05%. The production cost is decreased by 17.19% at the optimal solution. Finally, the proposed CATB process shows a great potential to replace the traditional techniques which are used to machine non-ferrous metals.

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Extended model for selection of optimum turning conditions based on minimum energy considerations

Cited by 6 publications

References 18 publications

Process parameter selection for laser welding of aluminium alloy from the perspective of energy effectiveness

Process parameter selection for laser welding of aluminium alloy from the perspective of energy effectiveness

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

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

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