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https://doi.org/10.5821/disser...
Doctoral thesis . 2023 . Peer-reviewed
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Specific energy consumption of metal cutting with thin abrasive discs

Authors: Awan, Muhammad Rizwan;

Specific energy consumption of metal cutting with thin abrasive discs

Abstract

The aim of this research is to provide an in-depth understanding of energy consumption in abrasive disc cutting processes. The specific energy consumed in cutting is measured,analysed, and then characterised in to three components. To this end, an experimental device is built using an Arduino-controlled grinder to measure the specific energy consumed by cutting at different feed rates. Using a model, the experimental data is validated and the Specific Energy Consumed is separated into three energy components: sliding, ploughing and specific cutting energy. Furthermore, the influence of cutting conditions and material properties significantly influenced the specific energy consumption and its components. To analyse the effect of grain shape and the relative dependence of the different components of the Specific Energy Consumed as a function of material removal rate, integral models of specific ploughing energy, specific sliding energy and specific cutting energy are developed. Conventional and super abrasive cubitron abrasive grains were used. Cutting with pyramidal abrasive discs (cubitron) was used for the determination of the relative components of the specific energy consumed. It was found that the specific ploughing energy is more sensitive to the change in material removal rate compared to the sliding energy. Due to the fast shearing and precisely shaped cubitron grains, the transition from sliding to a specific shear regime was so fast for some materials that the magnitude of the ploughing energy was found to be negligible.However, the model implementation for some materials showed that the absence or presence of ploughing energy also depends on the rate of material removed. Finally, the development of a cutting grain model is presented which will allow the study of the chip compression ratio which is not possible to characterise by means of a single cutting grain in metal cutting with thin abrasive discs. This latest development is the beginning of a study of chip formation in the primary cutting zone of an abrasive grain. This research provides a machine and a methodology to characterise cutting with commercially available abrasive discs in terms of the Specific Energy Consumed parameter. El objetivo de esta investigación es proporcionar un conocimiento profundo sobre el consumo de energía en los procesos de corte con discos abrasivos. Se mide y analiza la energía específica consumida en el corte, caracterizando dicha energía en tres componentes. Para ello se construye un dispositivo experimental que utiliza una amoladora controlada por un Arduino, para medir la energía específica consumida por el corte a diferentes velocidades de alimentación. Utilizando un modelo, se validaron los datos experimentales y se separa la Energía Específica Consumida en tres componentes energéticos: deslizamiento, arado y energía de corte específica. Además, la influencia de las condiciones de corte y las propiedades del material influyeron significativamente en el consumo de energía específico y sus componentes. Para analizar el efecto de la forma del grano y la dependencia relativa de las diferentes componentes de la Energía Específica Consumida en función de la tasa de remoción de material. Se desarrollan modelos integrales de energía de arado específica, energía de deslizamiento específica y energía de corte específica. Se utilizaron granos abrasivos convencionales y súper abrasivos de Cubitrón. El corte con discos abrasivos de granos piramidales (cubitron) se utilizaron para la determinación de las componentes relativas de la energía específica consumida. Se encontró que la energía de arado específica es más sensible al cambio en la tasa de remoción de material en comparación con la energía de deslizamiento. Debido a los granos de Cubitrón de corte rápido y de forma precisa, la transición de deslizamiento a un régimen de corte específico fue tan rápida para algunos materiales que la magnitud de la energía de arado resultó ser insignificante. Sin embargo, la implementación del modelo para algunos materiales demostró que la ausencia o presencia de energía de arado también depende de la tasa de material removido. Por último se presenta el desarrollo de un modelo de grano de corte que permitirá estudiar la relación de compresión de la viruta que no es posible caracterizar a través de un solo grano de corte en el corte de metales mediante discos abrasivos delgados. Este último desarrollo es el comienzo de un estudio de la formación de viruta en la zona primaria de corte de un grano abrasivo. Esta investigación proporciona una máquina y una metodología para caracterizar el corte con disco abrasivos, disponibles comercialmente, en términos del parámetro Energía Específica Consumida.

Country
Spain
Keywords

:Enginyeria mecànica [Àrees temàtiques de la UPC], 621, Àrees temàtiques de la UPC::Enginyeria mecànica, 531/534

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selected citations
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This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
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