Coupling evaluation for material removal and thermal control on precision milling machine tools

doi:10.1007/s11465-021-0668-9

Front. Mech. Eng.

2022, Vol. 17

Issue (1) : 12 https://doi.org/10.1007/s11465-021-0668-9

RESEARCH ARTICLE

Coupling evaluation for material removal and thermal control on precision milling machine tools

Kexu LAI¹, Huajun CAO¹(

), Hongcheng LI², Benjie LI³, Disheng HUANG¹

¹. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
². School of Advanced Manufacturing Engineering, Chongqing University of Posts and Telecommunication, Chongqing 400065, China
³. College of Mechatronic Engineering, Southwest Petroleum University, Chengdu 610500, China

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Abstract

Machine tools are one of the most representative machining systems in manufacturing. The energy consumption of machine tools has been a research hotspot and frontier for green low-carbon manufacturing. However, previous research merely regarded the material removal (MR) energy as useful energy consumption and ignored the useful energy consumed by thermal control (TC) for maintaining internal thermal stability and machining accuracy. In pursuit of energy-efficient, high-precision machining, more attention should be paid to the energy consumption of TC and the coupling relationship between MR and TC. Hence, the cutting energy efficiency model considering the coupling relationship is established based on the law of conservation of energy. An index of energy consumption ratio of TC is proposed to characterize its effect on total energy usage. Furthermore, the heat characteristics are analyzed, which can be adopted to represent machining accuracy. Experimental study indicates that TC is the main energy-consuming process of the precision milling machine tool, which overwhelms the energy consumption of MR. The forced cooling mode of TC results in a 7% reduction in cutting energy efficiency. Regression analysis shows that heat dissipation positively contributes 54.1% to machining accuracy, whereas heat generation negatively contributes 45.9%. This paper reveals the coupling effect of MR and TC on energy efficiency and machining accuracy. It can provide a foundation for energy-efficient, high-precision machining of machine tools.

Keywords machine tools cutting energy efficiency thermal stability machining accuracy coupling evaluation

Corresponding Author(s): Huajun CAO

About author:

Miaojie Yang and Mahmood Brobbey Oppong contributed equally to this work.

Just Accepted Date: 11 March 2022 Issue Date: 29 April 2022

Cite this article:

Kexu LAI,Huajun CAO,Hongcheng LI, et al. Coupling evaluation for material removal and thermal control on precision milling machine tools[J]. Front. Mech. Eng., 2022, 17(1): 12.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-021-0668-9
https://academic.hep.com.cn/fme/EN/Y2022/V17/I1/12

Fig.1 Functional units of a typical milling machine tool.

Fig.2 Coupling relationship between MR and TC. (a) Power versus energy consumption and machining accuracy, (b) power versus cutting energy efficiency.

Fig.3 Power consumption profile of typical milling.

Fig.4 Typical end milling with a milling cutter.

Fig.5 Heat generation and dissipation of main spindle.

Fig.6 Heat generation and dissipation of cutting area.

Level	Cutting speed, $v c$ /(m?min^?1)	Feed per tooth, $a f$ /(mm?z^?1)	Depth of cut, $a p$ /mm
1	15	0.05	0.5
2	18	0.10	1.0
3	21	0.15	1.5

Tab.1 Cutting parameters and their levels

Experimental group	$v c$ /(m·min⁻¹)	$a f$ /( mm·z⁻¹)	$a p$ /mm
1	15	0.05	0.5
2	18	0.10	0.5
3	21	0.15	0.5
4	18	0.05	1.0
5	21	0.10	1.0
6	15	0.15	1.0
7	21	0.05	1.5
8	15	0.10	1.5
9	18	0.15	1.5

Tab.2 Detailed information of orthogonal experiments

Fig.7 Trajectory of the cutting tool during cutting process.

Fig.8 Milling experimental setup: (a) milling cutter and workpiece, (b) temperature data acquisition device and laptop, (c) dial gauge, (d) power bus of the machine tool (left), power and quality analyzer (right).

Fig.9 Power consumption profile of the 4th group during different operation stages.

Fig.10 Composition and proportion of total energy consumption.

Fig.11 Change of

η M R

before and after the cooling mode.

Fig.12 Heat characteristics and flatness error of each experimental group.

Fig.13 Comprehensive comparisons in energy consumption, cutting energy efficiency, and machining accuracy: (a) total energy consumption and cutting energy efficiency, (b) energy consumption and flatness error.

Fig.14 3D surface map of energy consumption, cutting energy efficiency, and flatness error.

$a e$	Cutting width
$a f$	Feed rate per tooth
$a p$	Depth of cut
$c A$	Specific heat capacity of compressed air
$c l i$	Specific heat capacity of auxiliary liquid
C_F, x_F, y_F, u_F, q_F, w_F, and $k F c$	Cutting coefficients
$C O P j$	Coefficient of performance of the jth TC unit
$d 0$	Diameter of cutting tool
$E b$	Energy consumed by basic functional units
$E c$	Cutting energy
$E f$	Energy requirements of feed motors during noncutting stage
$E m s$	Energy requirement of the main spindle during noncutting stage
$E M R$	Energy consumed by MR units
$E MR-c$	Constant energy requirement of main spindle and feed axes during noncutting stage
$E t c$	Energy requirement of the tool change system
$E t$	Total energy consumption of machine tool
$E T C$	Energy consumed by TC units
$E TC-u j$	Electricity consumption of the jth TC unit
$F c$	Cutting force
$G w$	Machining accuracy
$Δ L$	Thermal deformation of a certain component
$m ˙ A$	Mass flow rate of compressed air
$m ˙ l i$	Mass flow rate of auxiliary liquid
$m ˙ h a$	Mass flow rate of the hot air flowing into the electrostatic air filter
$n$	Rotation speed of the main spindle
$n 1$	Number of nozzles
$P b$	Power of basic operation
$P c$	Cutting power
$P i$	Power of the ith MR unit
$P k$	Power consumption of the kth basic unit
$P l$	Power loss related to MR
$P l a$	Power loss of amplifier
$P l i m$	Power loss of inner motor
$P l m f$	Power loss of mechanical transmission chains
$P M R$	Power consumed by MR
$P MR-c$	Power consumed by MR units during noncutting operation
$P T C$	Power consumed by TC
$P TC-c$	Power consumed by TC units during cooling operation
$P TC-s$	Power consumed by TC units during standby operation
$Q c$	Cutting heat
$Q c h$	Heat transferred to chips
$Q d$	Heat dissipation of machine tool
$Q d c a$	Heat taken away by compressed air
$Q d h a$	Heat dissipation of hot air
$Q d j$	Heat taken away by the jth TC unit
$Q d l i$	Heat taken away by auxiliary liquid
$Q g$	Heat generation of all heat sources
$Q ˙ g m s$	Heat generation of main spindle system
$Q t$	Heat transferred to cutting tool
$Q w p$	Heat transferred to workpiece
$t c$	Cutting time
$t h a$	Duration time of hot air
$t i$	Operating time of the ith MR unit
$t k$	Operating time of the kth basic-unit
$t l i$	Duration time of auxiliary liquid
$t A$	Usage time of compressed air
$T a$	Ambient temperature
$T h a$	Temperature of hot air
$T l i, i n$	Input temperature of auxiliary liquid
$T l i, o u t$	Output temperature of auxiliary liquid
$T o u t$	Air temperature at corresponding nozzle
$T s$	Temperature inside machine tool
$Δ T$	Temperature rise of a certain component
$v c$	Cutting speed
z	Tooth number of milling cutter
$η$	Convert efficiency of mechanical energy to heat
$η m$	Spindle motor efficiency
$η M R$	Cutting energy efficiency
$η T C$	Energy consumption ratio of TC
$δ F E$	Flatness error

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