Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding
Amelia Nápoles Alberro1, Hernán A González Rojas2, Antonio J Sánchez Egea3
1Department of Mechanical Engineering (EPSEVG), Universidad Politécnica de Cataluña, Av. de Víctor Balaguer, 1, Vilanova i la Geltrú, 08800 Barcelona, Spain. amelia.napoles@upc.edu.
Materials (Basel, Switzerland)
|March 24, 2019
Summary
This study models material removal rate to estimate specific energy consumption in industrial grinding. Sliding energy is the primary dissipation mechanism, decreasing with higher depth of cut and workpiece speed.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Energy Efficiency
Background:
- Grinding energy efficiency is crucial and influenced by cutting conditions, grinding wheels, and workpiece materials.
- Specific energy consumption estimation aids in controlling energy usage during grinding operations.
Purpose of the Study:
- To develop a material removal rate model for estimating specific energy consumption in plane surface grinding.
- To identify and evaluate power dissipation mechanisms (sliding, ploughing, chip formation) in industrial-scale grinding.
- To analyze the impact of abrasive grain positions on material removal rate.
Main Methods:
- Developed a model correlating material removal rate with active power consumption.
- Measured power consumption during plane surface grinding of C45K and AISI 304.
- Described instantaneous abrasive grain positions to study material removal.
Main Results:
- Validated the model against laboratory-scale specific chip-formation energy estimations.
- Identified sliding energy as the dominant energy dissipation mechanism in industrial grinding.
- Observed that sliding energy per unit volume decreases with increased depth of cut and workpiece speed.
Conclusions:
- The developed model accurately estimates specific energy consumption in industrial grinding.
- Sliding energy is the most significant factor in energy dissipation, influenced by process parameters.
- Optimizing depth of cut and workpiece speed can enhance grinding energy efficiency by reducing sliding energy.
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