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Plastic deformation-based energy consumption modelling for machining

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Abstract

To predict energy consumption in machining, a mathematical modelling method to mimic the cutting energy consumption during machining is proposed in this paper. The established model is based on the law of energy conservation. The mechanical material property coefficients and cutting parameters are included in the model by using material deformation theory and friction calculation which are used to represent the phenomena in machining. Cutting energy of material removal process is refined by analysing the effect of tool edge geometry. In addition, the machining process is divided into two machining elements, linear element and circular arc element, of which energy consumptions are established based on the principal theories above. Calculation method on the instantaneous cutting thickness for circular arc elements is proposed. Finally, a test example is given to validate the proposed modelling approach. With the proposed method, the separate impacts of the factors (e.g. cutting parameters, workpiece, tool) have been analysed and the physical background behind the known experimental dependence of the cutting parameters on cutting energy is revealed.

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Acknowledgments

The authors sincerely thank all the anonymous reviewers for their valuable suggestions on the improvement of our paper.

Funding

This work is supported in part by the National Natural Science Foundation of China (grant no. 51720105009).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin, 150080, China

    Yue Meng, Wei Ji & Xianli Liu

  2. Department of Production Engineering, KTH Royal Institute of Technology, Stockholm, 100 44, Sweden

    Lihui Wang & Wei Ji

  3. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430000, China

    Chen-Han Lee

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  1. Yue Meng
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  2. Lihui Wang
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  4. Wei Ji
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Correspondence to Yue Meng.

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Meng, Y., Wang, L., Lee, CH. et al. Plastic deformation-based energy consumption modelling for machining. Int J Adv Manuf Technol 96, 631–641 (2018). https://doi.org/10.1007/s00170-017-1521-5

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