The Experts below are selected from a list of 2598 Experts worldwide ranked by ideXlab platform
Paul T. Mativenga - One of the best experts on this subject based on the ideXlab platform.
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an investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in Mechanical Machining
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Isuamfon F. Edem, Vincent A. Balogun, Paul T. MativengaAbstract:Manufacturing sustainability and minimal environmental impacts of Machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that Machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling Machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath Machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in Mechanical Machining. This could further raise the integrity of sustainable Machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in Mechanical Machining and also reduce the environmental impacts.
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An investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in Mechanical Machining
International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Isuamfon F. Edem, Vincent A. Balogun, Paul T. MativengaAbstract:© 2017 Springer-Verlag LondonManufacturing sustainability and minimal environmental impacts of Machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that Machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling Machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath Machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in Mechanical Machining. This could further raise the integrity of sustainable Machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in Mechanical Machining and also reduce the environmental impacts.
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Specific Energy Based Characterization of Surface Integrity in Mechanical Machining
Procedia Manufacturing, 2016Co-Authors: Vincent A. Balogun, Paul T. MativengaAbstract:In Mechanical Machining operations, process mechanisms and Machining efficiency can be characterized by the cutting tool geometry, process parameters and workpiece materials. These variables are vital parameters to evaluating the specific cutting energy demand as indication to sustainable manufacture. In today's manufacturing environment, where minimum production cost is required to maximize profits, optimum performance of manufactured component is one of the pre-requisite to consumer's continuous patronage. The optimum performance of product especially in Machining can be linked to process mechanisms, specific energy demand and surface roughness. Surface integrity is known to vary with values of the ratio of un-deformed chip thickness to cutting edge radius. The specific energy demand is influenced as process mechanism changes. This raises the economic cost of manufacture and CO2 emission. In this work, surface integrity of Mechanically machined component is characterized and linked to its corresponding process mechanisms and specific energy demand. This work will contribute towards an improved process parameter selection for minimum energy demand, aid process planning, sustainable manufacture and resource efficiency for Mechanical Machining processes.
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impact of feed axis on electrical energy demand in Mechanical Machining processes
Journal of Cleaner Production, 2016Co-Authors: Isuamfon F. Edem, Paul T. MativengaAbstract:Abstract To reduce energy demand in manufacturing, it is important to make products using the most energy efficient process plan and resources. In Machining, understanding the factors that influence the electrical energy demand for CNC toolpaths is vital in order to determine the optimum Machining conditions to minimise energy demand. In this study, a new model for estimating the electrical energy demand of machine tool feed axes which incorporates the weights of feed axes and weights of the materials placed on the machine table is presented. This was achieved by studying the electrical energy demand for machine tools when air cutting in defined axis directions, carrying a range of masses, and in actual cutting, while the electrical current was measured. The newly proposed model was validated on milling CNC toolpaths. The information enabled the development of suggestions for reducing energy demand. The energy reduction hypothesis developed was explored and validated by Machining components in defined orientations on the machine table. The results are important for manufacturers in industry when process planning. The information is also valuable for the range of machine tool design and manufacturing companies in the development of energy efficient machine tools.
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impact of un deformed chip thickness on specific energy in Mechanical Machining processes
Journal of Cleaner Production, 2014Co-Authors: Vincent A. Balogun, Paul T. MativengaAbstract:Abstract Energy demand reduction is a grand challenge for manufacturing sustainability in order to reduce the escalating cost of energy and to cut down on the carbon footprint of manufacturing processes. The direct electrical energy requirements in manufacturing and Machining in particular can be modelled from the basic energy required by the machine tool and the energy for actual material removal (tip energy). However, energy centric modelling of manufacturing processes is in its infancy and related material processing data is limited and of low integrity. It has often been assumed that the specific cutting energy is a constant value for particular workpiece materials. This paper is inspired by the mechanistic force modelling and the size effect phenomenon in Machining. The aim of this work was to investigate the specific electrical energy demand in Machining and model its relationship to thickness of material removed. To this end, specific energy evaluated in cutting tests was empirically modelled. This work is comprehensive in that it covers a wide range of un-deformed chip thickness as well as three workpiece materials. A new and fundamental understanding of the variation of specific energy with chip thickness is reported for the first time. This can be an evidence base for a generic model for the dependence of specific energy on un-deformed chip thickness. This information is vitally important to raise the integrity of energy labelling of Machining processes and as a backbone to process optimisation in order to reduce electrical energy demand and promote manufacturing sustainability.
Isuamfon F. Edem - One of the best experts on this subject based on the ideXlab platform.
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an investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in Mechanical Machining
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Isuamfon F. Edem, Vincent A. Balogun, Paul T. MativengaAbstract:Manufacturing sustainability and minimal environmental impacts of Machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that Machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling Machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath Machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in Mechanical Machining. This could further raise the integrity of sustainable Machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in Mechanical Machining and also reduce the environmental impacts.
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An investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in Mechanical Machining
International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Isuamfon F. Edem, Vincent A. Balogun, Paul T. MativengaAbstract:© 2017 Springer-Verlag LondonManufacturing sustainability and minimal environmental impacts of Machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that Machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling Machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath Machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in Mechanical Machining. This could further raise the integrity of sustainable Machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in Mechanical Machining and also reduce the environmental impacts.
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impact of feed axis on electrical energy demand in Mechanical Machining processes
Journal of Cleaner Production, 2016Co-Authors: Isuamfon F. Edem, Paul T. MativengaAbstract:Abstract To reduce energy demand in manufacturing, it is important to make products using the most energy efficient process plan and resources. In Machining, understanding the factors that influence the electrical energy demand for CNC toolpaths is vital in order to determine the optimum Machining conditions to minimise energy demand. In this study, a new model for estimating the electrical energy demand of machine tool feed axes which incorporates the weights of feed axes and weights of the materials placed on the machine table is presented. This was achieved by studying the electrical energy demand for machine tools when air cutting in defined axis directions, carrying a range of masses, and in actual cutting, while the electrical current was measured. The newly proposed model was validated on milling CNC toolpaths. The information enabled the development of suggestions for reducing energy demand. The energy reduction hypothesis developed was explored and validated by Machining components in defined orientations on the machine table. The results are important for manufacturers in industry when process planning. The information is also valuable for the range of machine tool design and manufacturing companies in the development of energy efficient machine tools.
Eunchae Jeon - One of the best experts on this subject based on the ideXlab platform.
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study on ductile mode Machining of single crystal silicon by Mechanical Machining
International Journal of Machine Tools & Manufacture, 2017Co-Authors: Daehee Choi, Nari Kang, Taejin Je, Eunchae JeonAbstract:Abstract Nano patterns on single-crystal silicon are generally manufactured by photolithography, which can form limited cross-sectional shapes such as U-shapes or rectangular channels. Though V-shaped patterns are widely used in the optical industries because they concentrate light, they are challenging to manufacture by conventional photolithography. Mechanical Machining is useful in manufacturing various kinds of cross-sectional shapes including V-shapes with various apex angles, but is hard to apply to single-crystal silicon due to its brittle fracture. Here we suggest a novel way of Mechanical Machining of single-crystal silicon that suppresses brittle fracture below the critical point (the ductile-brittle transition point) as determined by nano-scratch testing. We find that the first drop point of the cutting force corresponds to a critical point and define the critical forces as the thrust force and the cutting force at the critical point. The critical forces are varied by the applied force per unit length, which is the possibility that the cutting tool interacts with Mechanically weak atomic bonds. When the applied force per unit length is zero (a general condition of Mechanical Machining), the cutting speed does not affect the variation of the critical forces or the quality of the machined pattern. Based on analysis of the experimental results, we suggest that the single-crystal silicon can be Mechanically machined without brittle fracture at high cutting speed if the thrust force is smaller than the critical force of zero applied force per unit length.
Vincent A. Balogun - One of the best experts on this subject based on the ideXlab platform.
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an investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in Mechanical Machining
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Isuamfon F. Edem, Vincent A. Balogun, Paul T. MativengaAbstract:Manufacturing sustainability and minimal environmental impacts of Machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that Machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling Machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath Machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in Mechanical Machining. This could further raise the integrity of sustainable Machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in Mechanical Machining and also reduce the environmental impacts.
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Specific Energy Based Characterization of Surface Integrity in Mechanical Machining
Procedia Manufacturing, 2016Co-Authors: Vincent A. Balogun, Paul T. MativengaAbstract:In Mechanical Machining operations, process mechanisms and Machining efficiency can be characterized by the cutting tool geometry, process parameters and workpiece materials. These variables are vital parameters to evaluating the specific cutting energy demand as indication to sustainable manufacture. In today's manufacturing environment, where minimum production cost is required to maximize profits, optimum performance of manufactured component is one of the pre-requisite to consumer's continuous patronage. The optimum performance of product especially in Machining can be linked to process mechanisms, specific energy demand and surface roughness. Surface integrity is known to vary with values of the ratio of un-deformed chip thickness to cutting edge radius. The specific energy demand is influenced as process mechanism changes. This raises the economic cost of manufacture and CO2 emission. In this work, surface integrity of Mechanically machined component is characterized and linked to its corresponding process mechanisms and specific energy demand. This work will contribute towards an improved process parameter selection for minimum energy demand, aid process planning, sustainable manufacture and resource efficiency for Mechanical Machining processes.
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impact of un deformed chip thickness on specific energy in Mechanical Machining processes
Journal of Cleaner Production, 2014Co-Authors: Vincent A. Balogun, Paul T. MativengaAbstract:Abstract Energy demand reduction is a grand challenge for manufacturing sustainability in order to reduce the escalating cost of energy and to cut down on the carbon footprint of manufacturing processes. The direct electrical energy requirements in manufacturing and Machining in particular can be modelled from the basic energy required by the machine tool and the energy for actual material removal (tip energy). However, energy centric modelling of manufacturing processes is in its infancy and related material processing data is limited and of low integrity. It has often been assumed that the specific cutting energy is a constant value for particular workpiece materials. This paper is inspired by the mechanistic force modelling and the size effect phenomenon in Machining. The aim of this work was to investigate the specific electrical energy demand in Machining and model its relationship to thickness of material removed. To this end, specific energy evaluated in cutting tests was empirically modelled. This work is comprehensive in that it covers a wide range of un-deformed chip thickness as well as three workpiece materials. A new and fundamental understanding of the variation of specific energy with chip thickness is reported for the first time. This can be an evidence base for a generic model for the dependence of specific energy on un-deformed chip thickness. This information is vitally important to raise the integrity of energy labelling of Machining processes and as a backbone to process optimisation in order to reduce electrical energy demand and promote manufacturing sustainability.
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modelling of direct energy requirements in Mechanical Machining processes
Journal of Cleaner Production, 2013Co-Authors: Vincent A. Balogun, Paul T. MativengaAbstract:The aim of this research was to contribute towards the development of a new mathematical model and logic for predicting direct electrical energy requirements in Machining toolpaths. This model will track the visibility and process dependence of energy and hence carbon footprint in Machining process. This study includes a critical review of similar existing models and their limitations. The effect that machine modules, auxiliary units and machine codes have on power and energy consumption during Machining was studied and the electrical current consumption measured. A mathematical model for electrical energy use in Machining was developed addressing the limitations of existing models and validated on a milling tool path. The paper provides valuable information on the impact of machine modules, spindles, auxiliary units and motion states on the electrical energy demand budget for a machine tool resource. This knowledge is fundamentally important in evaluating toolpaths and re-designing machine tools to make them more energy efficient, to reduce electricity costs and associated carbon footprints.
Daehee Choi - One of the best experts on this subject based on the ideXlab platform.
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study on ductile mode Machining of single crystal silicon by Mechanical Machining
International Journal of Machine Tools & Manufacture, 2017Co-Authors: Daehee Choi, Nari Kang, Taejin Je, Eunchae JeonAbstract:Abstract Nano patterns on single-crystal silicon are generally manufactured by photolithography, which can form limited cross-sectional shapes such as U-shapes or rectangular channels. Though V-shaped patterns are widely used in the optical industries because they concentrate light, they are challenging to manufacture by conventional photolithography. Mechanical Machining is useful in manufacturing various kinds of cross-sectional shapes including V-shapes with various apex angles, but is hard to apply to single-crystal silicon due to its brittle fracture. Here we suggest a novel way of Mechanical Machining of single-crystal silicon that suppresses brittle fracture below the critical point (the ductile-brittle transition point) as determined by nano-scratch testing. We find that the first drop point of the cutting force corresponds to a critical point and define the critical forces as the thrust force and the cutting force at the critical point. The critical forces are varied by the applied force per unit length, which is the possibility that the cutting tool interacts with Mechanically weak atomic bonds. When the applied force per unit length is zero (a general condition of Mechanical Machining), the cutting speed does not affect the variation of the critical forces or the quality of the machined pattern. Based on analysis of the experimental results, we suggest that the single-crystal silicon can be Mechanically machined without brittle fracture at high cutting speed if the thrust force is smaller than the critical force of zero applied force per unit length.
