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Energy modeling for variable material removal rate machining process: an end face turning case

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Abstract

Material-cutting energy modeling is the key technology of energy modeling of machining process, being the foundation of energy optimization. The material-cutting power changes dynamically during variable-material removal rate (MRR) machining process. Hence, the energy characteristic of variable-MRR machining process is more complicated than that of constant-MRR machining process. In this paper, a modeling method of material-cutting energy for variable-MRR machining process is proposed. The dynamic power characteristics are fully considered in this method, and the impacts of cutting parameters on material-cutting energy are also considered. Experimental studies were conducted to obtain the fitting coefficients of the proposed energy model. Finally, energy calculations of four actual end face turning processes were performed. The results show that the predictive accuracy of all tested end face turning cases is above 90 %. The proposed method provides an accurate energy model for process planning in metal cutting process, which helps manufacturers determinate the energy-optimal process plan.

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Authors and Affiliations

  1. Industrial Engineering Center, Zhejiang Province Key Laboratory of Advanced Manufacturing Technology, Zhejiang University, Hangzhou, 310027, China

    Shun Jia, Renzhong Tang & Zhongwei Zhang

  2. Shandong University of Science and Technology, Qingdao, 266590, China

    Shun Jia & Qinghe Yuan

  3. Xi’an Research Institute of Navigation Technology, Xi’an, 710068, China

    Jingxiang Lv

Authors
  1. Shun Jia
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  2. Renzhong Tang
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  3. Jingxiang Lv
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  4. Zhongwei Zhang
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  5. Qinghe Yuan
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Correspondence to Renzhong Tang.

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Jia, S., Tang, R., Lv, J. et al. Energy modeling for variable material removal rate machining process: an end face turning case. Int J Adv Manuf Technol 85, 2805–2818 (2016). https://doi.org/10.1007/s00170-015-8133-8

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  • DOI: https://doi.org/10.1007/s00170-015-8133-8

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