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Energies 2015, 8(11), 13081-13095; doi:10.3390/en81112362

Selection of Cutting Inserts in Dry Machining for Reducing Energy Consumption and CO2 Emissions

1
Departamento de Ingeniería de Construcción y Fabricación, Universidad Nacional de Educación a Distancia (UNED), C/Juan del Rosal 12, Madrid 28040, Spain
2
Departamento de Ingeniería Mecánica, Química y Diseño Industrial, Universidad Politécnica de Madrid, Ronda de Valencia 3, Madrid 28012, Spain
*
Author to whom correspondence should be addressed.
Academic Editor: Mark Lemon
Received: 22 August 2015 / Revised: 25 October 2015 / Accepted: 9 November 2015 / Published: 18 November 2015
View Full-Text   |   Download PDF [2026 KB, uploaded 18 November 2015]   |  

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 (CO2-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 CO2-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. View Full-Text
Keywords: carbon dioxide emissions; energy; sustainability; turning; Ti6Al4V; insert carbon dioxide emissions; energy; sustainability; turning; Ti6Al4V; insert
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Domingo, R.; Marín, M.M.; Claver, J.; Calvo, R. Selection of Cutting Inserts in Dry Machining for Reducing Energy Consumption and CO2 Emissions. Energies 2015, 8, 13081-13095.

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