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Selection of Cutting Inserts in Dry Machining for Reducing Energy Consumption and CO 2 Emissions

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  • Rosario Domingo

    (Departamento de Ingeniería de Construcción y Fabricación, Universidad Nacional de Educación a Distancia (UNED), C/Juan del Rosal 12, Madrid 28040, Spain)

  • Marta María Marín

    (Departamento de Ingeniería de Construcción y Fabricación, Universidad Nacional de Educación a Distancia (UNED), C/Juan del Rosal 12, Madrid 28040, Spain)

  • Juan Claver

    (Departamento de Ingeniería de Construcción y Fabricación, Universidad Nacional de Educación a Distancia (UNED), C/Juan del Rosal 12, Madrid 28040, Spain)

  • Roque Calvo

    (Departamento de Ingeniería Mecánica, Química y Diseño Industrial, Universidad Politécnica de Madrid, Ronda de Valencia 3, Madrid 28012, Spain)

Abstract

Manufacturing processes are responsible for climate change due to the emissions produced as result of energy consumption. This paper analyzes the influence of the cutting conditions and the characteristics of cutting tools on the energy required in machining processes and the carbon dioxide equivalent (CO 2 -eq) emissions generated per material removed ratio (MRR) in an effort to define common criteria for using cutting inserts in a sustainable manner. Consequently, four cutting inserts were evaluated during the turning of Ti6Al4V alloy. An experimental and statistical methodology that combined the orthogonal array L36, the signal-to-noise ratio under the “small is better” criterion of Taguchi, and a multifactor analysis of variance was used. The effects of the geometry, material and coating of the tool and the cutting conditions on the energy and the carbon footprint during the manufacturing process were analyzed. The results show that a high tool cutting length and a high cutting depth are significant common factors, whereas the coating-cutting depth and cutting length-cutting speed are significant common interactions for both the energy/MRR ratio and the CO 2 -eq emissions/MRR ratio, and the coating-cutting speed exhibits a significant interaction for emissions. The outcomes show that the lifespan of the tool has little influence on the total emissions, at the time that the methodology is able to identify the most appropriate manner to calculate energy.

Suggested Citation

  • Rosario Domingo & Marta María Marín & Juan Claver & Roque Calvo, 2015. "Selection of Cutting Inserts in Dry Machining for Reducing Energy Consumption and CO 2 Emissions," Energies, MDPI, vol. 8(11), pages 1-15, November.
    • Handle: RePEc:gam:jeners:v:8:y:2015:i:11:p:12362-13095:d:59004
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    References listed on IDEAS

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    1. Qiang Zhai & Huajun Cao & Xiang Zhao & Chris Yuan, 2011. "Cost Benefit Analysis of Using Clean Energy Supplies to Reduce Greenhouse Gas Emissions of Global Automotive Manufacturing," Energies, MDPI, vol. 4(10), pages 1-17, September.
    2. Marc A. Rosen, 2013. "Engineering and Sustainability: Attitudes and Actions," Sustainability, MDPI, vol. 5(1), pages 1-15, January.
    3. Xian-Chun Tan & Yan-Yan Wang & Bai-He Gu & Ze-Kun Mu & Can Yang, 2011. "Improved Methods for Production Manufacturing Processes in Environmentally Benign Manufacturing," Energies, MDPI, vol. 4(9), pages 1-19, September.
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    Cited by:

    1. Rosario Domingo & Beatriz De Agustina & Marta M. Marín, 2018. "A Multi-Response Optimization of Thrust Forces, Torques, and the Power of Tapping Operations by Cooling Air in Reinforced and Unreinforced Polyamide PA66," Sustainability, MDPI, vol. 10(3), pages 1-14, March.
    2. Shun Jia & Qingwen Yuan & Wei Cai & Qinghe Yuan & Conghu Liu & Jingxiang Lv & Zhongwei Zhang, 2018. "Establishment of an Improved Material-Drilling Power Model to Support Energy Management of Drilling Processes," Energies, MDPI, vol. 11(8), pages 1-16, August.
    3. Shun Jia & Qinghe Yuan & Dawei Ren & Jingxiang Lv, 2017. "Energy Demand Modeling Methodology of Key State Transitions of Turning Processes," Energies, MDPI, vol. 10(4), pages 1-19, April.

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