Produceer met minder engergie economisch en ecologisch verspanen - jef loenders

the collective centre of the Belgian technological industry

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Economisch en ecologisch [email protected]

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Today’s ECO-challenges in machining

10/11/2011© Sirris | www.sirris.be | [email protected] | 2

Increase of energy consumption and cost

Increase of material cost

Near net shapes

Energy-efficient use of auxillary devices (coolantpumps, compressor, lights, processor,…)

MQL or dry machining

Machining strategies

Process Simulation

Intelligent use of compressed air and coolant

Use of standby modes (chip conveyor, light, processor,…)

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Optimization of metal cutting of new ecological materials

Analysis of the energy balance of machine tools in different conditions

Entire analysis of the production process including the environmental aspect and development of

methods for increasing the efficiency.


Only implementing alternatives when there is an economical added value!

Scope

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“Ecology” and “Economy” are translated by this project in the efficient use of energy in machining processes and process chains by development of energy

friendly alternatives.

www.cornet-era.net

process

machinematerial

ECO2CUT

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Approach and objectives


Analysis energy

consumption

Optimization energy

efficiencySimulation

OK?

NOK?

WP5

Process A

Process B

Process C

Process D

Process X

… …

Process chain – WP6

Measurement standards

Measurements

Advanced materials

Cutting process

Implementation

Advanced materials

Cutting process

WP4 WP4

WP3 WP3

WP2

WP2

Specific for the companies

• Benchmark of the energy balance of the involved companies (often SME’s)ECO2-award •Propose and implement new alternatives• Evaluation of case studies• Support the SME’s concerning possible certification: EN16001 and ISO 50001

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Analysis of energy consumption in machiningprocesses

Power measurements E [kWh] = P [kW] x t [h]

Methodd: 3 watt-meter method Devices C.A 8335 Data Acquisition : “DataView”

Sample Rate : 50Hz


Total Power

Power sub-unit

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Energy consumption in turning aluminium

Total specific energy [J/mm³]

= Total energy per machined volume


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Total specific energy [J/mm³]

= sum of the energy for constant power (processor, fans, light, etc…) and variable power, dependend of process parameters (spindle speed, feedrate, cutting depth)


Energy for variable power demand

Energy for constant power demand

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There is an optimum cutting speed by high feed where the energyconsumption per mm³ machined volume is minimum.


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Energy analysis turning aluminium part


Drilling(centering)

Drilling

Turning(Facing)

Turning(Contouring)

GroovingCut-off

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Energy allocation turning aluminium part

10/11/2011 © Sirris | www.sirris.be | [email protected] |12

Relative energy consumption subunitsRelative energy consumption per feature/subprocess

50% of energy input : spindle and drives

25% of energy input : pumps

1/3 of total energy input is non-productive

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Optimisations in machining processes and processchains


Process parameters•Optimum cutting speed•Cutting depth•Feed rate

Programmablefunctions•Retract point•Optimisation non-cuttingtool path•Start point cooling•Minimize tool changes•Chip conveyor•MQL/Dry machining•Machining strategies

Auxiliary functions•Pumps•Compressor•Compressed air•Standby modus•Processor, lights,…

Product design•Starting geometry = near net shape

Energy management•Energy efficient processplanning

ECO-mechatronics•Frequency controlledmotors•Lightweight materials in machine tool design

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• Optimal vc selection

Energy Consumption and Surface Quality

vc ≥ 80 m/min

Ra=1.25 µm(Predefined)

vc = 300 m/min(Min. energy)

Surface roughness

TSE

Process parametersOptimum cutting speedCutting depthFeed rate

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Fast Movement Decreased total energy, decreased auxiliary energy, decreased drives’ energy

auxiliary energy decreasing

Moderate feed Ensure position accuracy

Fast Movement Increased Power

Process parametersOptimum cutting speedCutting depthFeed rate

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Programmable functionsRetract pointOptimisation non-cutting tool pathStart point coolingMinimize tool changesChip conveyorMQL/Dry machiningMachining strategies

Source: “Design and Operation Strategies for Green Machine Tool Development”, Laboratory for Manufacturing and Sustainability, University of California, Berkeley

Processing time and energy consumption ofvarious tool paths

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High speed milling aluminium part


Condenser

Roughing

Tool change+Calibration

1. Spindle off2. Tool change3. Spindle on4. Calibration5. Spindle off6. Spindle out of tool magazine7. Spindle on

Total power profile3 7

1 5

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High speed milling aluminium part


Condenser

Roughing

Tool change+Calibration

1. Spindle off2. Tool change3. Spindle on4. Calibration5. Spindle off6. Spindle out of tool magazine7. Spindle on

Total power profile3 7

1 5Reducing the power means: reducing average power in 15 minutes, so peak power willreduce!

Less energy and distribution costs!

Machining

By energy-friendly machiningstrategies, the power can bereduced with 50%!

15 minutes 15 minutes

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Case studies

• Questions• Does the acceleration from 5000 rpm towards 42000 rpm for high precision milling produces a power

peak? What could be a good alternative strategy for acceleration in spindle speed?

• What are the most energy-consuming subprocesses to produce this part?

• Are there general energy-saving potentials in manufacturing aluminium?

• How much energy does the robot consumes in idle time?

• Could we use the robot also as an automatic deburring machine to save labour costs?

• Is there another method or strategy for surface milling to minimise the energy consumption?

• There is no production in the weekend but I have to put my coolant pumps on to avoid algae and other dirt in the coolant water and coolant water tank. Is there another way or alternative so I canreduce the energy consumption in the weekend?

• What’s the consumption if we grind or turn (hard- and precision turning) a tolerance hole?

• What is the cost of compressed air?

• …


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Process chain aluminium part


Notes:Prod. Time: 16.5 minElectricity: 0.125 €/kWh1 year : 220 working days1 day : 8 hours

1%

Coolant pump: 8%Windows flushing pump: 14% To avoid chips on doors(have to open automatically)

Other devices 30% : Chip conveyor, lights, processor,compressors, … further research on the actorsof this consumption

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Process chain aluminium part


Sp.+Dr. Spindle A axis C axis (X,Y,Z) Axes

Energy [kJ] 3847.33 1021.6 103.38 56.92 2665.43

Percent 100% 26.55% 2.69% 1.48% 69.28%

Retract point for tablerotation can be improved(only Z-translation)

Optimised feed and spindlespeed

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Cost of Compressed air leaks

• Compressor IR MH 11

• Period of measurement: 7 days

• Type of measurement: flowmeasurement with currentclamps

• Average consumption: 0.54m³/min

• Leakage: 0.35m³/min


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• Compressor IR MH 11

• Period of measurement: 7 days

• Type of measurement: flowmeasurement with currentclamps

• Average consumption: 0.54m³/min

• Leakage: 0.35m³/min


Leak0

0,1

0,2

0,3

0,4

leak useful

[m³/

min

]

Consumption compressed air

Optimization

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Overall analysis

• Compressor electricity cost / year : € 11.627 and € 1.200 on maintenance

• Constant leak of 350 l/min (day and night) • some machine unmanned production at night, so compressor can not be turned off

• Older and historically expanded compressed air net

• Compressor switches on 5 times per hour (day and night)• Too many leakages

• Installed pressure on the compressor is 10 bar• Normally 6.8 bar is sufficient

• One machine is consuming a lot of compressed air

• Every machine has a blowing pistol (old models) with a consumption of 400l/min


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Optimizations

• Compressor electricity cost / year : € 11.627 and € 1.200 on maintenance

0,35

0,08

0

0,1

0,2

0,3

0,4

0,5

0,6

before after

Consumption compressed air [m³/min]

leak

useful

Reduce leaksSavings: € 6000 a

year

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Optimisations

• Installed pressure on the compressor is 10 bar• Normally 6.8 bar is sufficient

• One machine is consuming a lot of compressed air detailled analysis energy footprint machine is needed

• Every machine has a blowing pistol (old models) with a consumption of 400l/min

Replace old pistols with new Venturi blow mouths : more air volume, less consumption


Source: Phibo Industries

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Minimum quantity of lubrication

• Main reasons of implementing MQL in the machine tool:• Improved surface quality (less surface roughness) as a result of 100 % lubrication

• Selling price for near-dry chips is higher then wet chips

• Less waste of oil

• Recycling wet chips is more difficult

• More maintenance with emulsion coolant: filters, refill emulsion coolant,…

• Main reasons of not implementing MQL:• Parts have to be cleaned after machining

• Spray of oil need ventilation system and filter

• Trend: Dry machiningmore expensive cutting tools


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Minimum quantity of lubrication


Source: “Evaluation of the Environmental Impact of different Lubrorefrigeration Conditions in Milling of y-TiAl Alloy”, Department of Production Systems and Business Economics, Politecnico di Torino, Turin , Italy

Dry machining

Wet machining

MQL

Lubricant condition Total absorbed power

Dry 1.35 kW

Wet 1.51 kW

MQL 3.90 kW

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Near net shape

• Machining near net shape model (layer manufactured, casted,…)• Less chip waste

• Precision manufacturing only there where necessary: tolerances, roughnesses, fittings,…

Total Production Time and Economical benefits?


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• Movement of peak period to a quiet period

• Same energy consumption as in the past, moved in time

Practical example

NIKO , a company in Sint-Niklaas (switching materials, door communication systems, lighting control and home automation

systems) bought a software programm to analyse their energy consumption. They followed their peak power en this led to several

changes to a high reduction in their peak power. They changed the line of galvanisation to the night in this spares them 15% of the

energy bill per year!Source: Voka.be


Source: “Optimizing Energy Costs by Intelligent Production Scheduling”, Department of Mechanical Engineering, University of Applied Sciences Emden/Leer, Emden, Germany

Energy managementEnergy efficient process planning

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Benchmark product

• Objectives• To compare energy consumption of machine tools

(same family: 5-axis, 3-axis, turning, turn-milling machines) in several companies

• To analyse the "energy delta" between a benchmark product made without taking care of energy-friendly alternatives and strategies and one made with these optimizations

• To make the same product periodically (e.g. 6 months, per year,…) on a machine tool to analyze when maintenance is needed, to have a good maintenance plan

• The benchmark product is designed considered accuracy as well, so it could fullfil a double role


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• 2-3 times/year meeting with presenting results, progress of research project and discussion

• Access to website: Wiki ECO2-CUT

Steering Group

35

https://wiki.sirris.be/display/ECO2CUT/Home�

Produceer met minder engergie economisch en ecologisch verspanen - jef loenders

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