Eventos Anais de eventos
COBEM 2023
27th International Congress of Mechanical Engineering
Study of Electrical Energy Consumption in Milling Surfaces Under Different Machining Conditions
Submission Author:
Joao Carlos Espindola Ferreira , SC , Brazil
Co-Authors:
Raphael Xavier, Joao Carlos Espindola Ferreira, Adriano Adriano Fagali de Souza
Presenter: Joao Carlos Espindola Ferreira
doi://10.26678/ABCM.COBEM2023.COB2023-1632
Abstract
The study of electrical energy consumption during machining is relevant to (a) reducing the electric power consumed by the machine during machining, (b) monitoring tool life, and (c) obtaining the final cost of the produced part. Machining strategies influence the machine's electrical energy consumption and machining time, but few works have been found in the literature that investigated such influence. Given this scenario, the objective of this work was to evaluate the influence of machining strategies, the cutting speed, depths of cut, and feed parameters on the electrical energy consumption in milling AISI P20 steel parts with different part geometries. Initially, the acquisition of electric power in roughing was investigated, machining in 2.5D with different cutting parameters. Subsequently, the electric power consumption and the mean roughness Ra were obtained in finish milling the mold of a connecting rod using the following strategies generated by the NX software: zigzag, contour parallel, zig, and concentric zigzag. A carbide ball-end mill was used for finishing, and the influence of tool wear was also investigated. Then, the electric power consumption was examined in milling a complex surface using a G-code numerical control (NC) program generated by the NX software and a modified G-code program. Non-cutting machining tests were also carried out to obtain the electrical energy generated by other devices present in the machine. The tests were performed using a 4-axis Romi D 600 CNC milling machine. A signal conditioner was used to measure the power and electrical energy consumed in the spindle, and a system available in the CNC Fanuc called "S1 load" that measures the load in relation to the spindle speed. The machining strategy with the lowest energy consumption was the contour parallel. Several peaks of electric power consumption occurred in the concentric zigzag strategy, and bands with more significant variation in electric power at the end of the G-code program. The zig and zigzag strategies had electric power peaks at the beginning of the G-code programs. The zigzag strategy resulted in the lowest mean roughness among the studied strategies. Using the modified G-code program led to higher electric power consumption during finish milling but reduced machining time.
Keywords
Milling Strategies, Electric Energy Consumption, machining, Sustainable Manufacturing
