Quantitative Analysis And Optimizatioof Energy Consumption And Carbon Footprint In Grinding Processes

Low-carbon Manufacturing is essential for achieving Low-Carbon EconomyPattern. To accurately quantify carbon dioxide emission in manufacturing processes is aprerequisite for low-carbon Manufacturing. Grinding is a widely used precisionmachining method. The proportion of grinding machine in workshops reflects a nation’smanufacturing level of development. The grinding process consumes more specificenergy than turning or milling and the hyperthermal grinding zone needs a large amountof grinding fluid usage, whose disposal has enormous impact on the environment,what’s more, regular grinding wheel dressing is also an inevitable consumption processof energy and resources. Therefore, grinding is a heavy energy consumption, highresource depletion and waste emission machining method.In this dissertation, a qualitative analysis of factors influencing efficient andlow-carbon grinding has been carried out using axiomatic design based method.Considering the relationship among energy, resources, wastes and carbon dioxideemission, ERWC carbon dioxide emission calculation model has been established forthe grinding process. Among this stage, a novel approach to quantize energyconsumption in the grinding process called Four-power Model has been proposed.Based on the model, efficient and low-carbon grinding machining strategies have beenfurther developed, which has formed the foundation for low-carbon CNC machining.The research purpose and scientific significance have been detailed as well as thestate-of-the art in the field of low-carbon manufacturing are discussed in Chapter I.After that, the main research topics and the dissertation framework are described.Diverse energy consumption of a CNC grinding machine has been analysed inChapter II. On this basis, this chapter explores energy consumption within grindingprocess using both empirical and theoretical formulas in a quantitative way. The energyconsumption in the grinding process has been divided into material removal energyconsumption, basic energy consumption, frequency-converted energy consumption andresponse energy consumption, which is called Four-power Model. Each of the fourkinds of energy consumption has been described in a mathematical relationship withgrinding process parameters. The research results contribute to the study of quantitativeassessment of energy consumption and its impact on carbon emissions in grindingprocessed.An axiomatic model on the efficient and low-carbon grinding as the highestfunctional requirement has been presented firstly in Chapter III. Resources consumedand wastes generated in the grinding process have been quantified. At this stage, thegrinding wheel usage, fluid consumption, lubricant applied and workpiece chipsdisposal have been described in mathematical relationships with grinding process parameters. Using carbon dioxide emission database, ERWC carbon dioxide emissioncalculation model for the grinding process has been established step by step. In thisprocess, actual grinding energy consumption experiments have been carried out so as toobtain desired energy consumption data. Computational analysis of comparablegrinding parameters and key influencing factors has been undertaken within Matlabenvironment.An multi-objective optimization model with the linear speed of grinding wheel andguide wheel, feed rate and time in both roughing stage and finishing stage as controlvariables has been established in Chapter IV. A set of feasible grinding parameters hasbeen obtained using genetic algorithms. The results can not only lead decreasedgrinding time and carbon emissions, but also meet the conditions for highly efficientand effective grinding, as supported by comparative experiments. The experimentalresults show that the optimized grinding parameters reduces energy consumption, andalso verifies the accuracy and robustness of the model. As result, the axiomatic modelfrom the perspective of optimizing grinding parameters has been completed. A visualhuman-computer interactive interface of efficient and low-carbon grinding parameteroptimization has been developed, which has formed the foundation for the ERWCmodel application in the field of low-carbon manufacturing optimization.