Process Optimization Of Green EDM For Energy Efficiency

Manufacturing industry consumes huge amounts of energy and emits serious pollution,which has a huge impact on global resources and the environment.For now,research on energy consumption in the energy saving and emission reduction strategy of manufacturing process is the only way to achieve sustainable development.Compared with traditional machining methods,electrical discharge machining(EDM)is a non-traditional machining method widely used in mold,automotive,aerospace and other industries.In this paper,amorphous alloy(BMG)and metal alloy are two representative metal materials,aiming at the problems of energy consumption,low energy consumption control and machining effect in EDM machining process,and the prediction model of EDM energy consumption and low energy consumption control strategy method are put forward.And the energy consumption is discussed from the aspects of workpiece material,optimization method of cutting parameter framework and dielectric.The specific research is as follows:Firstly,we established the corresponding heat distribution model in EDM.On this basis,the calculation model of machining energy consumption is established by combining the electrical parameter information and technological parameters of machining amorphous alloy.The prediction of energy consumption in the experimental stage of designing EDM amorphous alloy is realized.Through the experimental comparison,the average error of MRR and EEV can reach 16.99% and 16.46% respectively,which is consistent with the experimental results,which proves that the numerical model can be applied to engineering applications.The proposed thermophysical model is basically consistent with the EDM of amorphous alloy.In the experiment,the machining performance is analyzed by the over-cutting value of drilling notch,and the feasibility of EDM machining amorphous alloy is explored.Secondly,the energy consumption in the process of EDM metal alloy is studied.We use the Fuzzy Reasoning System(ANFIS)based on if-then strategy to establish a mapping model for predicting EDM performance and environmental sustainability.The mapping model can be used to analyze the interaction between process parameters and output.The effects of process parameters on MRR,processing performance of surface roughness(Ra)and exhaust emission performance(EEC)are studied by mapping model and signal-to-noise ratio mean analysis.Lay the foundation for the follow-up work of sustainable manufacturing.Experiments show that the required maximum MRR can be achieved when the peak current is 10 A,and the required minimum Ra can be achieved when the peak current is 6A.Similarly,the required minimum EEV can be achieved when the peak current is 10 A,and the required minimum EEC can be achieved when the peak current is 6A.Through the verification of ANFIS model,the maximum average relative error is 13.04%.Thirdly,in order to realize the sustainability and green manufacturing of EDM,the machining of metal alloys Al 6061,SKD 11 and Inconel 718 is studied by using environmentally friendly renewable vegetable oil as the dielectric of EDM.The processability and energy efficiency per unit volume of sunflower oil,rapeseed oil and peanut oil are compared in order to find a cheap and sustainable dielectric.The influence of viscosity change of EDM medium on EDM performance is explained from the perspective of machining mechanism.By comparison,MRR of rapeseed oil as dielectric is 25% and 28.9% higher than peanut oil and sunflower seed oil,and EEV is 5% and 27% lower than peanut oil and rapeseed oil,respectively.In addition,the proportion of residues with different particle sizes in the medium is studied by ultra-depth of field optical microscope,which verified the rationality of the above mechanism.Because of the high viscosity of rapeseed oil,concentrated discharge energy and greater impact force on the workpiece,the proportion of chips with a diameter larger than 35?m is the largest.Finally,the environmental impact and long-term viability of renewable dielectrics are discussed to realize the sustainability and green manufacturing of EDM.Finally,in order to meet the requirements of green manufacturing and environmental sustainability,a multi-objective optimization framework based on enhanced cuckoo algorithm is proposed.Take the most common metal alloy material processing in manufacturing industry as an example.In order to minimize energy consumption and exhaust emissions,the framework of technological parameters in the EDM process of Al 6061 and SKD 11 is optimized.The MRR,Ra,EEV and EEC of EDM of these two materials were tested by using three process parameters: peak current,pulse period and duty cycle.After the calculation of the optimization framework,it is suggested that the processing parameters of high peak current(8.94A),pulse period(500?s)and duty cycle(0.7)should be used to process Al 6061,and the optimal solutions of EEV and EEC are reduced by 87.13% and 37.09% respectively.Similarly,the processing performance of SKD 11 is reduced by 93.73% and 46.85% for EEV and EEC,respectively.This topic has practical application significance to the development of intelligent manufacturing with energy saving and emission reduction as the theme through energy consumption prediction analysis of EDM process.