Cutting Process Parameters Optimization Test Research For Minimizing Energy Consumption Of CNC Lathes

At present,social economic development is faced with the challenges of the sharp drop in the Earth's resources and environmental degradation,and low carbon and energy saving have become the urgent needs of the society.The number of machine tools in China occupies the first place in the world,which has a huge space for energy saving and emission reduction.In the machining process with machine tools,the depth of cut,feed rate,cutting speed and the parameters of cutting tools have great influences on work-piece machining quality,production efficiency,energy consumption and carbon emissions.Based on orthogonal experiment tests,this paper analyzes the relationships among energy consumption,processing time and cutting process parameters using analysis of variance(ANOVA),range analysis and Taguchi robust design method,and determines optimal cutting process parameters.The main research contents include:(1)A CNC lathe energy consumption test system is established.Based on orthogonal experiment design,the energy consumption is tested for machining 45 steel and using the cutting fluid with cemented carbide tool.The test results show that depth of cut,feed rate and cutting speed have significant influences on the total energy consumption,average power.The combination of the maximal factor levels makes the total energy consumption and processing time minimum and robust.The optimal and robust factor level combination for the average power is depth of cut 0.25 mm,feed rate 0.10 mm/r and cutting speed 62.5 m/min.The feed rate and cutting speed are significant for the surface roughness,and depth of cut is not significant.From the point of the minimal and robust surface roughness,the optimal level combiniation of three factors is the depth of cut 0.50 mm,feed rate 0.05 mm/r and cutting speed 75 m/min.(2)The orthogonal experiment of the energy consumption not using the cutting fluid shows that the optimal and robust cutting parameter combination for the total energy consumption and processing time is the same as the situation while using the cutting fluid.The minimal and robust level combination for the average power is depth of cut 0.25 mm,feed rate 0.15 mm/r and cutting speed 50 m/min.The minimal and robust level combination for the surface roughness is depth of cut 0.25 mm,feed rate 0.15 mm/r and cutting speed 75 m/min.The contrastive analysis of test results with or not using cutting fluid indicates that the energy consumption and average power significantly decrease while not using the cutting fluid.The surface roughness increases under the test conditions while not using the cutting fluid,and seriously affected by the cutting speed.(3)The orthogonal experiment analysis of the energy consumption about cutting speed,feed rate and cutting edge angle indicates that the cutting speed and feed rate have significant influences on total energy consumption and average power,and cutting edge angle has insignificant influence.The cutting edge angle is significant for the surface roughness,and cutting speed and feed rate is insignificant.Under the given test conditions,the optimal and robust factor combination for the total energy consumption is depth of cut 0.75 mm,feed rate 0.15 mm/r and cutting edge angle 50°.The optimal and robust level combination for the average power is depth of cut 0.25 mm,feed rate 0.05 mm/r and cutting edge angle 75°.The optimal and robust level combination for the surface roughness is depth of cut 0.25 mm,feed rate 0.1 mm/r and cutting edge angle 93°.Depth of cut has biggest influence on the processing time and the cutting edge angles has smallest influence.This paper will provide supports for manufacturing enterprises choosing cutting parameters and tool angle to reduce energy consumption and carbon emissions,and improve machining efficiency and processing quality in the production process.