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A holistic machining line behavior modeling using Finite State Machines
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2014 (English)Independent thesis Advanced level (degree of Master (Two Years)), 10 credits / 15 HE creditsStudent thesis
Abstract [en]

Energy consumption of turning and milling operations are analyzed in this thesis profoundly. It is aimed to be able to employ analysis results in real production floors. So it is tried to investigate on most effective parameters on machine tool energy consumptions which are changeable in production floors. Due to existing limitations in predesigned manufacturing lines, cutting depth, feed rate and spindle speed, are chosen to analyze their effects on machine tools energy consumption. All other influencing parameters are presumed constant during research. Evaluating machine tools energy consumption shows increasing machining factors values reduces energy consumption in machining operation. Scrutinizing machining factors effect on energy consumption revealed that, increasing one machining factor when two other factors have constant low or constant high values has different effect on energy consumption. The main contribution of this research is proposing a mathematical model, based on material removal rate and machining time for estimating machine tools energy consumption. In addition, a methodology to find machine energy consumption profile based on MRR in a particular operation is proposed too. This enables to find critical breakpoints of MRR for energy consumption in machining operations. Subsidiary effect of increasing Machining factors, on machine energy consumption is analyzed too. To obtain integrative conclusion regarding the effect of machining factors on energy consumption, their influence should be studied in a production system, for long term. In addition machines experience different states with different profile of energy consumption. So energy consumption of machine tools in all states is considered as product associated energy consumption. These targets are achieved by modeling a production line and simulate it for long time. The results indicates for system energy efficiency, it worth’s to increase machining factors even if tool life and consequently machine utilization reduce. Effect of production planning such as batch mode production from energy consumption perspective in production system is evaluated. The results exhibit consistency between tool life, machine idle energy consumption and optimum batch size. The accomplishments can greatly help process planner to achieve optimum production system configuration to enhance energy efficiency.

Place, publisher, year, edition, pages
2014. , 77 p.
, Degree Project in Production Engineering Management, Second Level, 585
National Category
Engineering and Technology
URN: urn:nbn:se:kth:diva-142035OAI: diva2:699643
Available from: 2014-02-28 Created: 2014-02-28 Last updated: 2014-02-28Bibliographically approved

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