SUNConferences, Southern African Institute for Industrial Engineering 2014

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INVESTIGATING THE EFFECT OF TOOL WEAR AND SURFACE INTEGRITY ON ENERGY EFFICIENCY DURING THE MACHINING OF TI-ALLOYS
Gert Adriaan Oosthuizen, Nicholas Tayisepi, Rudolph Frans Laubscher

Last modified: 2014-06-26

Abstract


Manufacturing processes carried out on  modern  machine tools are  still  energy  and resourceintensive.  In order to comply with future sustainability legislations and standards theseprocesses  should become  more  energy and resource  efficient. The strategic objective of companies still remains to increase  the production throughput rate, reduce  the inventory and operating costs while keeping the products within the quality constraints of the voice of the customer. Increasing the  material removal rates  (MRR)  will  influence  the  energy efficiency, tool failure rate  and  the work piece’s  surface integrity.  Thus, a better understanding of the  effects  cutting  mechanisms  have on energy  efficiency  during high speed  machining  (HSM) are gaining interest.  In this  research study  the effect of various cutting conditions on surface integrity,  tool wear  and  energy efficiency  were investigated.Cutting speed and feed rate were varied while the depth of cut was kept constant during theturning of Ti6Al4V under flood lubrication. Tool wear and surface roughness both deteriorated with an increase in  the  material removal rate. It was also found that worn cutting tools produced a higher work piece surface hardness than a new tool. The energy usage  for a specific cutting distance also  decreased with an increase in material removal rate. Future work is also outlined.


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