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Prediction of energy consumption and environmental implications for turning operation using finite element analysis
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0002-5960-2159
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
2015 (English)In: Proceedings of the Institution of mechanical engineers. Part B, journal of engineering manufacture, ISSN 0954-4054, E-ISSN 2041-2975, Vol. 229, no 11Article in journal (Refereed) Published
Abstract [en]

This article is concerned with the experimental and numerical investigation of energy consumption involved in the turning of Ti6Al4V titanium alloys. Energy consumption of a machining process is considered as an important machining performance indicator. This article aims to propose an approach for the prediction of energy consumption and related environmental implications using finite element modeling simulations. Machining experiments were conducted using uncoated carbide tools under dry cutting environment. DEFORM-3D software package was utilized to simulate finite element–based machining simulations. Experimental validation was mainly conducted by focusing on the cutting forces and power consumption measurements. Simulated results of the cutting force and power consumption were found in a good agreement with the experimental findings. The amount of CO2 emission resulting from energy consumption during the machining phase is highly dependent on the geographical location. This study also incorporated the energy mix of United Arab Emirates for the environmental calculations. Finally, in the light of proposed methodology, possible future directions and recommendations have also been presented.

Place, publisher, year, edition, pages
Sage Publications, 2015. Vol. 229, no 11
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-173593DOI: 10.1177/0954405414541105ISI: 000366158800005Scopus ID: 2-s2.0-84960934913OAI: oai:DiVA.org:kth-173593DiVA: diva2:853765
Note

QC 20150107

Available from: 2015-09-15 Created: 2015-09-15 Last updated: 2017-12-04Bibliographically approved
In thesis
1. Numerical and Experimental Investigations of the Machinability of Ti6AI4V: Energy Efficiency and Sustainable Cooling/ Lubrication Strategies
Open this publication in new window or tab >>Numerical and Experimental Investigations of the Machinability of Ti6AI4V: Energy Efficiency and Sustainable Cooling/ Lubrication Strategies
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Titanium alloys are widely utilized in the aerospace, biomedical,marine, petro-chemical and other demanding industries due to theirdurability, high fatigue resistance and ability to sustain elevateoperating temperature. As titanium alloys are difficult to machine, dueto which machining of these alloys ends up with higher environmentalburden. The industry is now embracing the sustainable philosophy inorder to reduce their carbon footprint. This means that the bestsustainable practices have to be used in machining of titanium alloys aswell as in an effort to reduce the carbon footprint and greenhouse gas(GHG) emissions.In this thesis, a better understanding towards the feasibility of shiftingfrom conventional (dry and flood) cooling techniques to the vegetableoil based minimum quantity cooling lubrication (MQCL) wasestablished. Machining performance of MQCL cooling strategies wasencouraging as in most cases the tool life was found close to floodstrategy or sometimes even better. The study revealed that theinfluence of the MQCL (Internal) application method on overallmachining performance was more evident at higher cutting speeds. Inaddition to the experimental machinability investigations, FiniteElement Modeling (FEM) and Computational Fluid Dynamic (CFD)Modeling was also employed to prediction of energy consumed inmachining and cutting temperature distribution on the cutting tool. Allnumerical results were found in close agreement to the experimentaldata. The contribution of the thesis should be of interest to those whowork in the areas of sustainable machining.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. xx, 136 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 15:07
Keyword
Titanium alloys, Energy consumption, Wear mechanisms, Finite element analysis, computational fluid dynamic analysis
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-173594 (URN)978-91-7595-702-9 (ISBN)
Public defence
2015-10-01, Brinellsal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20150915

Available from: 2015-09-15 Created: 2015-09-15 Last updated: 2015-09-15Bibliographically approved

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Amir, Rashid

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