Coupling evaluation for material removal and thermal control on precision milling machine tools
Tóm tắt
Machine tools are one of the most representative machining systems in manufacturing. The energy consumption of machine tools has been a research hotspot and frontier for green low-carbon manufacturing. However, previous research merely regarded the material removal (MR) energy as useful energy consumption and ignored the useful energy consumed by thermal control (TC) for maintaining internal thermal stability and machining accuracy. In pursuit of energy-efficient, high-precision machining, more attention should be paid to the energy consumption of TC and the coupling relationship between MR and TC. Hence, the cutting energy efficiency model considering the coupling relationship is established based on the law of conservation of energy. An index of energy consumption ratio of TC is proposed to characterize its effect on total energy usage. Furthermore, the heat characteristics are analyzed, which can be adopted to represent machining accuracy. Experimental study indicates that TC is the main energy-consuming process of the precision milling machine tool, which overwhelms the energy consumption of MR. The forced cooling mode of TC results in a 7% reduction in cutting energy efficiency. Regression analysis shows that heat dissipation positively contributes 54.1% to machining accuracy, whereas heat generation negatively contributes 45.9%. This paper reveals the coupling effect of MR and TC on energy efficiency and machining accuracy. It can provide a foundation for energy-efficient, high-precision machining of machine tools.
Tài liệu tham khảo
Khatib H. IEA world energy outlook 2010—a comment. Energy Policy, 2011, 39(5): 2507–2511
Park C W, Kwon K S, Kim W B, Min B K, Park S J, Sung I H, Yoon Y S, Lee K S, Lee J H, Seok J. Energy consumption reduction technology in manufacturing—a selective review of policies, standards, and research. International Journal of Precision Engineering and Manufacturing, 2009, 10(5): 151–173
Cai W, Liu C H, Lai K H, Li L, Cunha J, Hu L K. Energy performance certification in mechanical manufacturing industry: a review and analysis. Energy Conversion and Management, 2019, 186: 415–432
Cai W, Lai K H. Sustainability assessment of mechanical manufacturing systems in the industrial sector. Renewable and Sustainable Energy Reviews, 2021, 135: 110169
Wang Q L, Liu F, Li C B. An integrated method for assessing the energy efficiency of machining workshop. Journal of Cleaner Production, 2013, 52: 122–133
Mouzon G, Yildirim M B, Twomey J. Operational methods for minimization of energy consumption of manufacturing equipment. International Journal of Production Research, 2007, 45(18–19): 4247–4271
Gutowski T, Dahmus J, Thiriez A. Electrical energy requirements for manufacturing processes. In: Proceedings of the 13th CIRP International Conference on Life Cycle Engineering. Leuven: CIRP, 2006, 623–628
Sihag N, Sangwan K S. A systematic literature review on machine tool energy consumption. Journal of Cleaner Production, 2020, 275: 123125
He Y, Liu F, Wu T, Zhong F P, Peng B. Analysis and estimation of energy consumption for numerical control machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2012, 226(2): 255–266
Liu F, Xie J, Liu S. A method for predicting the energy consumption of the main driving system of a machine tool in a machining process. Journal of Cleaner Production, 2015, 105: 171–177
Xie J, Cai W, Du Y B, Tang Y, Tuo J B. Modelling approach for energy efficiency of machining system based on torque model and angular velocity. Journal of Cleaner Production, 2021, 293: 126249
Chen X Z, Li C B, Tang Y, Li L, Li H C. Energy efficient cutting parameter optimization. Frontiers of Mechanical Engineering, 2021, 16(2): 221–248
Li P L, Cheng K, Jiang P Y, Katchasuwanmanee K. Investigation on industrial dataspace for advanced machining workshops: enabling machining operations control with domain knowledge and application case studies. Journal of Intelligent Manufacturing, 2022, 33(1): 103–119
Katchasuwanmanee K, Bateman R, Cheng K. Development of the energy-smart production management system (e-ProMan): a big data driven approach, analysis and optimisation. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016, 230(5): 972–978
Mayr J, Jedrzejewski J, Uhlmann E, Donmez M A, Knapp W, Härtig F, Wendt K, Moriwaki T, Shore P, Schmitt R, Brecher C, Würz T, Wegener K. Thermal issues in machine tools. CIRP Annals-Manufacturing Technology, 2012, 61(2): 771–791
Denkena B, Abele E, Brecher C, Dittrich M A, Kara S, Mori M. Energy efficient machine tools. CIRP Annals, 2020, 69(2): 646–667
Moradnazhad M, Unver H O. Energy consumption characteristics of turn-mill machining. The International Journal of Advanced Manufacturing Technology, 2017, 91(5–8): 1991–2016
Li B J, Cao H J, Hon B, Liu L, Gao X. Exergy-based energy efficiency evaluation model for machine tools considering thermal stability. International Journal of Precision Engineering and Manufacturing: Green Technology, 2021, 8(2): 423–434
Okwudire C, Rodgers J. Design and control of a novel hybrid feed drive for high performance and energy efficient machining. CIRP Annals: Manufacturing Technology, 2013, 62(1): 391–394
Wang Q L, Liu F. Mathematical model of multi-source energy flows for CNC machine tools. Journal of Mechanical Engineering, 2013, 49(7): 5–12 (in Chinese)
Wen L, Zein A, Kara S, Herrmann C. An investigation into fixed energy consumption of machine tools. In: Proceedings of the 18th CIRP International Conference on Life Cycle Engineering. Leuven, 2011, 268–273
Yang X, Cao H J, Zhu L B, Li B J. A 3D chip geometry driven predictive method for heat-loading performance of hob tooth in high-speed dry hobbing. The International Journal of Advanced Manufacturing Technology, 2017, 93(5–8): 1583–1594
Zhu L B, Cao H J, Zeng D, Yang X, Li B J. Multi-variable driving thermal energy control model of dry hobbing machine tool. The International Journal of Advanced Manufacturing Technology, 2017, 92(1–4): 259–275
Cao H J, Zhu L B, Li X G, Chen P, Chen Y P. Thermal error compensation of dry hobbing machine tool considering workpiece thermal deformation. The International Journal of Advanced Manufacturing Technology, 2016, 86(5–8): 1739–1751
Großmann K. Thermo-energetic Design of Machine Tools. Berlin: Springer International Publishing, 2015
Zailani Z A, Hamidon R, Hussin M S, Hamzas M F M A, Hadi H. The influence of solid lubricant in machining parameter of milling operation. International Journal of Engineering Science and Technology, 2011, 3(6): 5221–5226
Brecher C, Jasper D, Fey M. Analysis of new, energy-efficient hydraulic unit for machine tools. International Journal of Precision Engineering and Manufacturing-Green Technology, 2017, 4(1): 5–11
Zhao G Y, Liu Z Y, He Y, Cao H J, Guo Y B. Energy consumption in machining: classification, prediction, and reduction strategy. Energy, 2017, 133: 142–157
ISO. Machine tools—environmental evaluation of machine tools—Part 1: design methodology for energy-efficient machine tools. 2017. Available at ISO website
Walsh R A. Handbook of Machining and Metalworking Calculations. New York: McGraw-Hill, 2001, 159–174
Fu G Q, Tao C, Xie Y P, Lu C J, Gao H L. Temperature-sensitive point selection for thermal error modeling of machine tool spindle by considering heat source regions. The International Journal of Advanced Manufacturing Technology, 2021, 112(9–10): 2447–2460
Denkena B, Bergmann B, Klemme H. Cooling of motor spindles—a review. The International Journal of Advanced Manufacturing Technology, 2020, 110(11–12): 3273–3294
Iqbal A, Zhang H C, Kong L L, Hussain G. A rule-based system for trade-off among energy consumption, tool life, and productivity in machining process. Journal of Intelligent Manufacturing, 2015, 26(6): 1217–1232
Wu D W. A new approach of formulating the transfer function for dynamic cutting processes. Journal of Engineering for Industry, 1989, 111(1): 37–47
Zhu K P, Zhang Y. A generic tool wear model and its application to force modeling and wear monitoring in high speed milling. Mechanical Systems and Signal Processing, 2019, 115: 147–161
Yang X, Cao H J, Chen Y P, Zhu L B, Li B J. An analytical model of chip heat-carrying capacity for high-speed dry hobbing based on 3D chip geometry. International Journal of Precision Engineering and Manufacturing, 2017, 18(2): 245–256
Kozai T, Sakaguchi S, Akiyama T, Yamada K, Ohshima K. Design and management of PFALs. In: Kozai T, Niu G, Takagaki M, eds. Plant Factory. 2nd ed. Salt Lake City: Academic Press, 2020, 357–375