Sustainable machining: selection of optimum turning conditions based on minimum energy considerations

Abstract The aim of the work reported in this paper was to develop a new model and methodology for optimising the energy footprint for a machined product. The total energy of machining a component by the turning process was modelled and optimised to derive an economic tool-life that satisfies the minimum energy footprint requirement. The work clearly identifies critical parameters in minimising energy use and hence reducing the energy cost and environmental footprint. Additionally, the paper explores and discusses the conflict and synergy between economical and environmental considerations as well as the effect of system boundaries in determining optimum machining conditions.

[1]  Steven R Schmid Kalpakjian,et al.  Manufacturing Engineering and Technology , 1991 .

[2]  Sami Kara,et al.  Carbon emissions and CES™ in manufacturing , 2008 .

[3]  Paul Mativenga,et al.  Machinability Analysis from Energy Footprint Considerations , 2008 .

[4]  Claudio Boer,et al.  The incoming global technological and industrial revolution towards competitive sustainable manufacturing , 2008 .

[5]  E. Westkämper,et al.  Life Cycle Management and Assessment: Approaches and Visions Towards Sustainable Manufacturing (keynote paper) , 2000 .

[6]  Sri Hinduja,et al.  An Optimum Two-tool Solution for Milling 2½D Features from Technological and Geometric Viewpoints , 2004 .

[7]  Paul Mativenga,et al.  Energy and carbon footprint analyis for machining titanium Ti-6Al-4V alloy in High Performance Manufacturing Processes , 2009 .

[8]  S. R. S. Kalpakjian.  Manufacturing Processes for Engineering Materials , 1984 .

[9]  Peter Krajnik,et al.  Transitioning to sustainable production – Part I: application on machining technologies , 2010 .

[10]  Timothy G. Gutowski,et al.  An Environmental Analysis of Machining , 2004 .

[11]  Li Shu,et al.  The need for global coordination in sustainable development , 2009 .

[12]  M. Rogante.  Wear characterisation and tool performance of sintered carbide inserts during automatic machining of AISI 1045 steel , 2009 .

[13]  Paul Mativenga,et al.  Energy and carbon footprint analyis for machining titanium Ti-6Al-4V alloy , 2009 .

[14]  Kai Cheng,et al.  Modeling flank wear of carbide tool insert in metal cutting , 2005 .

[15]  Wim Dewulf,et al.  Improvement Potential for Energy Consumption in Discrete Part Production Machines , 2007 .

[16]  J. Peklenik,et al.  Some Basic Relationships for Identification of the Machining Processes , 1992 .

[17]  Jong-Leng Liow,et al.  Mechanical micromachining: a sustainable micro-device manufacturing approach? , 2009 .

[18]  Jan-Eric Ståhl,et al.  A general economic model for manufacturing cost simulation , 2008 .

[19]  Paul Mativenga,et al.  Machinability analysis from energy footprint considerations, in INTELIGENT MANUFACTURING FOR INDUSTRIAL BUSINESS PROCESSES , 2008 .

[20]  D. Alting,et al.  The Life Cycle Concept as a Basis for Sustainable Industrial Production , 1993 .

[21]  David N. Kordonowy,et al.  A power assessment of machining tools , 2002 .