Modeling energy consumption inside cutting deformation zone to predict the stress distributions, temperature and microstructure by micro irreversible entropic thermodynamics

Tang, Zhengyi; Huang, Chuanzhen; Shi, Zhenyu; Liu, Hanlian; Chen, Zhe; Li, Binghao; Niu, Jiahui; Chen, Zengtao

doi:10.1016/j.jmapro.2023.05.029

Cited by 3 publications

(2 citation statements)

References 37 publications

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“…From Equation (20), when the cutting tool with rounded corners undergoes wear, the flank face friction power generated in the contact area between the cutting tool and the workpiece is shown in Equation (21). The tool-workpiece contact area after sharp-edged tool wear is shown in Figure 4.…”

Section: Friction Power Of Flank Facementioning

confidence: 99%

“…Wang et al [20] revealed the effects of tool and cutting depth on the chip deformation behavior and the associated energy consumption based on the finite element method (FEM). Tang et al [21] took into account the energy consumption in the metal cutting process when analyzing the chip formation process and established the energy consumption field in the cutting deformation zone. Guo et al [22] proposed a method to optimize the cutting parameters in finish turning by taking into account both energy consumption and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

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Cutting Energy Consumption Modeling by Considering Tool Wear and Workpiece Material Properties for Multi-Objective Optimization of Machine Tools

Meng,

Dong,

Sun

et al. 2024

Coatings

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The increasing demand for energy is leading to global depletion of fossil fuels and growing environmental pressures, which are issues that need to be addressed. Machine tools are basic energy-consuming equipment in manufacturing systems. However, existing theoretical models ignore tool wear as well as workpiece material properties. This makes it difficult to further improve the accuracy of the model. Therefore, this study begins with the point of view of energy dissipation in the metal material removal process. A milling power model for computer numerical control (CNC) machines, considering tool wear and workpiece material properties during machining, is established. At the same time, milling is taken as the research object. A multi-objective cutting parameter optimization model is established to ensure the surface quality of the workpiece. In addition, the cutting energy consumption is taken into account in the developed models. Based on the multi-objective manta ray foraging optimization algorithm (MOMRFO), the Pareto-optimal solution set under multiple cutting conditions is solved. Finally, the experimental results of optimized parameters are compared with empirical parameters. The average prediction accuracy of the proposed energy consumption prediction model is above 91%. The experiments show that machining quality improves by optimizing the cutting parameters, with SEC, MRR, and Ra increasing by more than 44%, 53%, and 38%, respectively. The goals of reducing energy consumption and increasing productivity are achieved.

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Section: Friction Power Of Flank Facementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Cutting Energy Consumption Modeling by Considering Tool Wear and Workpiece Material Properties for Multi-Objective Optimization of Machine Tools

Meng,

Dong,

Sun

et al. 2024

Coatings

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Mechanical analysis prior to the steady-state cutting of TC4 titanium alloy

Hu,

Yuan,

Zou

et al. 2024

Measurement

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A novel approach for assessing the wear status of a milling tool flank based on the entropy generation of friction and thermal conduction

Zhao,

Ma,

Jiang

et al. 2024

Preprint

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High-efficiency milling cutters are extensively used in the manufacturing industry due to their excellent cutting performance. However, milling vibrations lead to variation in frictional stress and frictional velocity at the tool-worker friction interface so the thermodynamic behavior of a cutter-worker friction system is complex and variable, this makes the wear prediction of the milling cutter’s flank face in the milling process difficult. In this paper. we first developed a model for transient cutting behavior under vibration; based on this, a model for transient contact friction between the flank face of a high-efficiency milling cutter’s teeth and the machining transition surface was developed, and the friction stress and friction velocity at the characteristic points of the flank face were solved with the help of simulation data. The structure of the frictional thermodynamic system of the flank face of the milling cutter teeth was decomposed, and the entropy generation model of friction force due to nonlinear friction variables in the process of high-efficiency milling under the tool offset and different contact angle positions due to milling vibration was developed, as well as the entropy generation model of the milling heat transfer process under frictional extrusion in the third deformation zone. Finally, the wear depth of the tool flank was predicted based on the thermodynamic entropy generation which were used as one of the input variables. The results showed that the relative prediction error of the prediction model was 1.7%, confirming the good accuracy of the prediction model.

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Modeling energy consumption inside cutting deformation zone to predict the stress distributions, temperature and microstructure by micro irreversible entropic thermodynamics

Cited by 3 publications

References 37 publications

Cutting Energy Consumption Modeling by Considering Tool Wear and Workpiece Material Properties for Multi-Objective Optimization of Machine Tools

Cutting Energy Consumption Modeling by Considering Tool Wear and Workpiece Material Properties for Multi-Objective Optimization of Machine Tools

Mechanical analysis prior to the steady-state cutting of TC4 titanium alloy

A novel approach for assessing the wear status of a milling tool flank based on the entropy generation of friction and thermal conduction

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