This study aimed to investigate the impact of cutting parameters, cutting speed (vc), depth of cut (ae), and feed per tooth (fz), on energy consumption, active power, and energy efficiency during the milling of Ti-6Al-4V alloy with sinusoidal tool paths on CNC machine tools. The methodology included experimental trials with energy data collection at the CNC machine input using a power quality analyzer. A 23 factorial experimental design was employed to define machining parameters for the tests. Experimental results showed that increasing in the cutting speed and depth of cut significantly raised the mean active power and energy consumption. However, operating at higher cutting speeds and feed per tooth resulted in optimized energy efficiency, with the most efficient configuration being vc of 85 m/min, fz of 0.16 mm/tooth, and ae of 1.0 mm, achieving approximately 27.5% greater efficiency compared to the least efficient configuration. These findings highlight the importance of selecting appropriate cutting parameters to maximize energy efficiency in machining processes, contributing to sustainable manufacturing practices.

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Energy Efficiency in Machine Tools: Impact of Cutting Parameters on Sinusoidal Paths

  • Marie Madeleine Sarzi Inacio,
  • Rodrigo Henriques Lopes da Silva,
  • Amauri Hassui

摘要

This study aimed to investigate the impact of cutting parameters, cutting speed (vc), depth of cut (ae), and feed per tooth (fz), on energy consumption, active power, and energy efficiency during the milling of Ti-6Al-4V alloy with sinusoidal tool paths on CNC machine tools. The methodology included experimental trials with energy data collection at the CNC machine input using a power quality analyzer. A 23 factorial experimental design was employed to define machining parameters for the tests. Experimental results showed that increasing in the cutting speed and depth of cut significantly raised the mean active power and energy consumption. However, operating at higher cutting speeds and feed per tooth resulted in optimized energy efficiency, with the most efficient configuration being vc of 85 m/min, fz of 0.16 mm/tooth, and ae of 1.0 mm, achieving approximately 27.5% greater efficiency compared to the least efficient configuration. These findings highlight the importance of selecting appropriate cutting parameters to maximize energy efficiency in machining processes, contributing to sustainable manufacturing practices.