Ecodesign of the Aluminum Bronze Cutting Process

Area of Science:

• Materials Science
• Manufacturing Engineering
• Tribology

Background:

• High-property material production often demands substantial energy.
• Machining processes are critical for product realization but can be energy-intensive.
• Aluminum bronze alloys (C62300) are valuable but require efficient processing.

Purpose of the Study:

• To optimize the cutting process for aluminum bronze (C62300).
• To reduce energy consumption during machining.
• To establish correlations between cutting power and machined surface roughness.

Main Methods:

• Focused on machining a Ø = 20 mm semi-finished aluminum bronze product.
• Measured cutting forces in three directions (Fx, Fy, Fz).
• Evaluated three distinct cutting tool construction variants.
• Assessed the power consumed during the cutting process.

Main Results:

• A specific cutting tool variant reduced power consumption by approximately 30%.
• The same tool variant achieved surface roughness reductions of 90-100%.
• Statistical analysis confirmed the relationship between tool design, power, and surface finish.

Conclusions:

• Selecting the appropriate cutting tool variant is crucial for efficient aluminum bronze machining.
• Significant reductions in both energy use and surface roughness are achievable.
• The study recommends specific tool variants for roughing operations to maximize efficiency and quality.