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Home > Analysis of Specific Cutting Energy Consumption During Machining of Al 6061-T6 Alloy, Using the Energy Map Approach

Analysis of Specific Cutting Energy Consumption During Machining of Al 6061-T6 Alloy, Using the Energy Map Approach

Thesis Info

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External Link

Author

Warsi, Salman Sagheer

Program

PhD

Institute

National University of Sciences & Technology

City

Islamabad

Province

Islamabad

Country

Pakistan

Thesis Completing Year

2018

Thesis Completion Status

Completed

Subject

Manufacturing Engineering

Language

English

Link

http://prr.hec.gov.pk/jspui/bitstream/123456789/10760/1/Salman_Sagheer_Warsi_Manufaturing%20_Eng_2019_NUST_21.03.2019.pdf

Added

2021-02-17 19:49:13

Modified

2024-03-24 20:25:49

ARI ID

1676727702274

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There is an increased emphasis on energy efficiency of manufacturing processes owing to their negative impact on environment. Machining is one of the most widely used process in the manufacturing industry and accounts for more than 15% value in the globally manufactured products. Electrical energy consumption is considered as the major source of environmental and economic impact of machining processes. A number of studies can be found in literature that model and optimize energy consumption in machining processes. However, most of these studies employ power and energy as response variables that makes them machine tool specific. Therefore a generalized machine tool independent approach needs to be developed for energy consumption analysis in machining processes. This research addresses this problem by utilizing specific cutting energy as a response variable. Specific cutting energy takes into account cutting power and material removal rate and is independent of machine tool. A novel specific cutting energy map approach has been presented in this research. Al 6061-T6 alloy has been used as the workpiece material owing to its extensive application in automotive, aerospace and other high-tech products. The developed energy maps can represent specific cutting energy consumption in the form of different regions (very high, high, moderate, low and very low) against varying cutting condition. The energy map approach has been applied in conventional, transitional and high speed machining ranges. The formation of specific cutting energy regions has been investigated and it has been shown that these regions are strongly related with mechanics of cutting process in terms of: shear angle, chip ratio, chip formation, and contact length. It has been shown that energy saving up to 52% in machining of Al 6061 alloy can be achieved by selecting appropriate cutting parameters from the developed energy maps. The undeformed chip thickness was observed to be the most influential machining parameter affecting specific cutting energy consumption. The developed energy maps also revealed the presence of an avoidance zone associated with high cutting speeds and low undeformed chip thickness. Built-up edge was observed to be responsible for formation of avoidance zone.
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51:01
a. And the scatterers, scattering everywhere,

51:02
a. and the bearers with their burden,

51:03
a. and the runners with their gentle ease,

51:04
a. and the distributors by command!

51:05
a. Surely what you are promised is true indeed!

51:06
a. Surely the Time of Final Judgment is sure to come.

51:07
a. And the celestial realm with all its countless tracks!

51:08
a. Surely you are of differing opinions.

51:09
a. Whoever is deluded about it is really deluded.

51:10
a. So doomed be those who just speculate,

51:11
a. those who are oblivious of the realm of the Hereafter.

51:12
a. They mockingly ask:
b. ‘When will be the Time of Final Judgment?’

51:13
a. Tell them:
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51:14
a. And they will be told:
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c. This is what you had been seeking to hurry.’

51:15
a. Surely the virtuous will be in the Paradise and flowing springs;

51:16
a. receiving what their Rabb - The Lord will have given them of the reward,
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a. For they will sleep only a little of the night...

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