Model Based Approach for Energy and Resource Efficient Machining Systems

Description

This book provides a concept to analyze and increase the energy and resource efficiency of machining systems. Machining systems are widely used to produce workpieces in large quantities and with complex geometrical shapes. These systems, however, are also relevant in terms of energy and resource consumption, which is strongly connected to the choice of cutting fluid strategy. Within the focus of the concept, cutting fluid connects the elements of the machining system and results in interactions between them. Based on this description and an extensive literature review, a modeling approach is developed that comprises the relations between process parameters, cutting fluid strategies, and relevant machining system elements. The performance of the machining system is assessed with regard to environmental, economic as well as technological indicators and improved by various organizational and technical measures. The exemplary application of the developed concept is carried out in the context of two case studies and also indicates the corresponding effects of improvement measures. Acknowledgments Contents Symbols and Abbreviations Upper Case Symbols Lower Case Symbols Greek Symbols Abbreviations List of Figures List of Tables 1 Introduction 1.1 Motivation and Scope 1.2 Research Objective and Approach References 2 Machining Systems and Impact of Cutting Fluids 2.1 Elements and Interactions in Machining Systems 2.2 Classification, Functions and Strategies of Cutting Fluids 2.3 Description of Relevant Elements of the Machining System 2.3.1 Machining Processes and Tool Preparation 2.3.2 Cutting Fluid System 2.3.3 Exhaust Air System 2.3.4 Workpiece and Scrap Treatment System 2.4 Peripheral Systems Within Machining Process Chains 2.5 Modeling of Machining Systems 2.5.1 Modeling Approach 2.5.2 Modeling of Environmental, Economic and Functional Performance Indicators 2.6 Preliminary Conclusion References 3 State of Research 3.1 Procedure and Overview of Research Approaches 3.2 Criteria for the Comparative Evaluation of Research Approaches 3.3 Evaluation of Selected Approaches 3.4 Derivation of Research Demand References 4 Concept Development 4.1 Framework for Concept Development 4.1.1 Definition of Objectives and Requirements 4.1.2 Concept Structure 4.2 Modeling of Machining System Elements 4.2.1 Description of Procedure 4.2.2 Machining Process Model 4.2.3 Peripheral Subsystem Model 4.2.4 Multiple Machining Systems and Process Chains 4.2.5 Model Overview and Connection 4.3 Environmental, Economic and Technological Impact 4.4 Improvement Measures 4.4.1 Description of Measures 4.4.2 Impact Visualization 4.5 Concept Implementation References 5 Exemplary Application of the Concept 5.1 Application to a Machining System 5.1.1 Analyzing and Evaluating a Machining System 5.1.2 Impact of Process Parameters and Cutting Fluid Strategies 5.1.3 Application of Improvement Measures 5.1.4 Demonstration of Further Possible Measures 5.2 Application to a Process Chain 5.2.1 Planning and Evaluating a Process Chain 5.2.2 Application of Further Improvement Measures 5.3 Overview and Comparison of Improvement Measures References 6 Summary, Discussion and Outlook 6.1 Summary 6.2 Discussion 6.3 Outlook References Appendix Regression Parameters Case Study Specification