Automotive Design and Production

JUL 2014

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41 about 25% is used to power pumps. Drilling down a bit more, for mach- ine tools, 24% of the total energy consumption is for the cutting fuid system. So the institute initiated a research project with machine tool builder DMG MORI ( us.dmgmori. com ), cutting tool manufacturer Sandvik Coromant ( sandvik. coromant.com ), pump manufacturer Grundfos ( us.grundfos.com ), and fuid system supplier Bosch Rexroth ( boschrexroth.com ) to determine the correlation between cutting fuids and tool life with the objec- tive of reducing the amount of energy required for the system. They tested turning, milling and drilling operations, assessing the correlation between the volume fow of fuids and tool life. They concluded that there is an optimal fow rate based on the tool, the operation and process parameters. So, for example, in an external cylindrical turning operation that was run at v c = 150 m/min, a p = 3 mm and d = 0.25 mm. The fow was adjusted from 2.2 to 6.8 liters/ min. And the determination was made that the optimal rate of fow is 4.5 liters/min, and that by using that setting, the amount of power required by the pump is 67%, without having a negative impact on tool life. Other tests were conducted on rough and fnish milling, with adjustments made to the energy supplied to the pump. In one test, they were able to reduce the overall energy consump- tion of the machine by 37% without sacrifcing part quality or productivity. Evidently, even if a company isn't machining parts in Germany, there is a huge advantage that can be realized in energy use reduction by paying attention to details, like the amount of fuid fow used during machining. t Although the cutting fuid system may not seem to be a major factor in terms of energy use, an industry- academic research project found that by adjusting the amount of fuid pumped during a machining operation, there can be a considerable efect on the overall energy consumption of a machine without having a deleterious efect on part quality or productivity. 0714ADP FEATURE Energy -- Digital Version.indd 41 6/17/2014 1:09:49 PM

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