Optimization of Single Point Machining Parameters for Minimum Energy Utilization

Abstract

In the present research, a tractor part (king pin) was considered for single point machining. Keeping in view the product dimensions and capability of existing machine in the given industry, optimum cutting parameters for minimum energy consumption were recommended by using process window optimization technique. The recommended parameters were depth of cut 2.5 mm, cutting velocity 172 m/min, spindle rpm 1,273, feed rate 0.4 mm/rev, and cutting time 0.52 min resulting in energy consumed per volume of 4.9 Ws/mm³. All these parameters were available on existing machine. This enabled the manufacturer to easily upgrade the changes without incurring additional cost like replacement of existing machine by more energy efficient machine like CNC. This method implemented in industry proved that energy consumed per volume of material removed decreased by 12.5 % and production rate increased by 48.5 %. The research therefore presents a simple methodology which can be easily implemented on single point machining process in any industry to obtain optimum parameters not only for minimizing energy consumption but also for increasing production rate and enhancing Green machining.