IJE TRANSACTIONS B: Applications Vol. 31, No. 5 (May 2018) 847-855    Article in Press

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V. A. Balogun and I. F. Edem
( Received: July 27, 2017 – Accepted in Revised Form: January 06, 2018 )

Abstract    This paper presents an approach to analytically determine the most energy efficient toolpath strategy in mechanical machining. This was achieved by evaluating the electrical energy requirement of the NC codes generated for the zag, zigzag, and rectangular contour toolpath strategies. The analytical method was validated by performing pocket milling on AISI 1018 steel with the considered toolpaths using a 3-axis Takisawa Mac-V3 milling machine. The rectangular contour toolpath was the most efficient in terms of the electrical energy demand of the feed axes and cycle time. Pocket milling with the zigzag toolpath strategy resulted in higher electrical energy demand of the feed axes and cycle time by 2% due to acceleration and deceleration characteristics of the machine tool feed axes execution at corners of the toolpath strategy adopted. Also, the electrical energy demand of the feed axes and cycle time for the zag toolpath were higher by 14% and 8%, respectively, due to the number of tool retracts as a result of the executed toolpath strategy. The experimental validation results showed good agreement with the analytical approach presented in this study. It can be deduced that for sustainable machining, the rectangular contour toolpath should be adopted since it has less tool retractions irrespective of the toolpath strategy adopted for machining. This could further enhance the selection of optimum green parameters by shop floor process engineers for sustainable manufacture of products.


Keywords    Energy Efficiency, modelling, Machining, Toolpath Strategies, NC Codes, Feed Axes.


چکیده    در این مقاله یک آنالیز تحلیلی برای تعیین کارآمدترین ابزار استراتژی در ماشینکاری مکانیکی ارائه شده است. این امر با ارزیابی انرژی الکتریکی مورد نیاز کدهای NC تولید شده برای راه حل های مسیرهای استراتژی زاگ، زایگاگ و خطوط مستطیلی ساخته شده است. روش تحلیلی با انجام مراحل جوش بر روی فولاد AISI 1018 با استفاده از دستگاه تراشکاری 3 محور Takisawa Mac-V3 مورد تایید قرار گرفت. این خط کش خطی مستطیل بیشتر از نظر تقاضای انرژی برق محور و زمان چرخه کارآمدترین بود. فرزکاری جیبی با استراتژی چرخش زیگزاگ موجب افزایش تقاضای انرژی الکتریکی در محورهای تغذیه و زمان چرخه به میزان 2 درصد به علت شتاب و ویژگی های کند شدن فرایندهای محور چرخش ماشین ابزار در گوشه های استراتژی ToolPath شده است. همچنین تقاضای انرژی الکتریکی برای محور تغذیه و زمان چرخه برای مسیر ابزار زاگ به ترتیب 14٪ و 8٪ بیشتر بوده اند، این مورد بخاطر تعداد ابزار استراتژی راه انداز اجرا شده است. دراین مطالعه نتایج اعتبار سنجی تجربی حاصل شده، توافق مطلوبی با آنالیز تحلیلی داشته اند. می توان نتیجه گرفت که برای ماشینکاری پایدار، خط کش خطی مستطیل شکل باید اتخاذ شود، زیرا این روش بدون در نظر گرفتن استراتژی toolpath به کمترین ابزار نیاز داشته، که برای ماشینکاری اتخاذ گردید. برای تولید محصول پایدار، انتخاب پارامترهای سبز بهینه توسط مهندسین فرایند کارخانه حائز اهمیت است.


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