Abstract
Machine tools have an impact on the environment due to their energy consumption. New strategies with focus on the reduction of the energy consumed by manufacturing processes have received significant attention owing to the rise of the electricity costs. This paper presents an experimental study related to the optimization of cutting parameters in turning of AISI 1018 steel. The aim of the study was to minimize the quantity of electrical energy required by the machine tool in order to perform the cutting operation. The material removal rate was set to a constant value in all the experimental trials so as to analyze the effect that the cutting parameters have on the energy consumed. Robust Design was used to determine the effects of the depth of cut, feed rate, and cutting speed on the energy required by the machine tool, considering two sources of noise in the experimental trials. The results of this work show that the techniques covered by the concept of Robust Design can be used to minimize the energy consumed and variation of the machining process.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Balogun VA, Mativenga PT (2013) Modelling of direct energy requirements in mechanical machining processes. J Clean Prod 41:179–186
Zein A, Li W, Herrmann C, Kara S (2011) Energy Efficiency Measurements for the Design and Operation of Machine Tools: An Axiomatic Approach. 18th CIRP Conference on Life Cycle Engineering 2011. 1: 274-279
Bhattacharya A, Das S, Majumber P, Batish A (2009) Estimating the effect of cutting parameters on surface finish and power consumption during high speed machining of AISI 1045 steel using Taguchi design and ANOVA. Prod Eng Res Dev 3:31–40
Fratila D, Caizar C (2011) Application of Taguchi method to selection of optimal lubrication and cutting conditions in face milling of AlMg3. J Clean Prod 19:640–645
Mativenga PT, Rajemi MF (2011) Calculation of optimum cutting parameters based on minimum energy footprint. CIRP Ann Manuf Technol 60:149–152
Asiltürk I, Neseli S (2011) Multi response optimisation of CNC turning parameters via Taguchi method-based response surface analysis. Measurement 45:785–794
Guo Y, Loenders J, Duflou J, Lauwers B (2012) Optimization of energy consumption and surface quality in finish turning. 5th CIRP Conference on High Performance Cutting 2012. 1: 512-517
Hanafi I, Khamlichi A, Mata Cabrera F, Almansa E, Jabbouri A (2012) Optimization of cutting conditions for sustainable machining of PEEK-CF30 using TiN tools. J Clean Prod 33:1–9
Newman ST, Nassehi A, Imani-Asrai R, Dhokia V (2012) Energy efficient process planning for CNC machining. CIRP J Manuf Sci Technol 5:127–136
Helu M, Behmannn B, Meier H, Dornfeld D, Lanza G, Schulze V (2012) Impact of green machining strategies on achieved surface quality. CIRP Ann Manuf Technol 61:55–58
Bhushan RK (2013) Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of Al alloy SiC particle composites. J Clean Prod 39:242–254
Yan J, Li L (2013) Multi-objective optimization of milling parameters—the tradeoffs between energy, production rate and cutting quality. J Clean Prod 52:462–471
Campatelli G, Lorenzini L, Scippa A (2014) Optimization of process parameters using a Response Surface Method for minimizing power consumption in the milling of carbon steel. J Clean Prod 66:309–316
Taguchi G, Chowdhury S, Wu Y (2005) Taguchi’s Quality Engineering Handbook. Wiley, Hoboken, New Jersey, pp 56–125
Montgomery DC (2009) Design and Analysis of Experiments. Wiley, New York
Kara S, Bogdanski G, Li W (2011) Electricity Metering and Monitoring in Manufacturing Systems. 18th CIRP Conference on Life Cycle Engineering 2011. 1: 1–10
Aggarwal A, Singh H, Kumar P, Singh M (2008) Optimizing power consumption for CNC turned parts using response surface methodology and Taguchi's technique—a comparative analysis. J Mater Process Technol 200:373–384
Klocke F (2011) Manufacturing Processes 1—Cutting. Springer – Verlag, Berlin, Germany, p 58
SANDVIK Coromant (2010) Corokey 2010. www.sandvik.com (accessed on 18.12.12)
Dahmus J, Gutowski T (2004) An Environmental Analysis of Machining. Proceedings of ASME International Mechanical Engineering Congress and R&D Exposition, pp. 13–19
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Camposeco-Negrete, C., de Dios Calderón Nájera, J. & Miranda-Valenzuela, J.C. Optimization of cutting parameters to minimize energy consumption during turning of AISI 1018 steel at constant material removal rate using robust design. Int J Adv Manuf Technol 83, 1341–1347 (2016). https://doi.org/10.1007/s00170-015-7679-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7679-9