Experimental Research of Energy Consumption of Austenitizing Heat-Treated Casting Fittings in Pipe Threading

Year 2019, Volume: 23 Issue: 5, 869 - 878, 01.10.2019

Burak Öztürk

https://doi.org/10.16984/saufenbilder.513294

Cited By: 4

Abstract

Energy
consumption is an important part of the production cost of mass production
industrial enterprises. The casting, heat treatment and threading processes
involved in the industrial production of fittings result in high energy
consumption. In serial production, the threading of pipe fittings is carried
out using high torque and low speed. The thin-walled designs of the fittings
lead to rapid cooling, causing the formation of a high rate of pearlite
microstructures and subsequent low or extremely hard machinability. Heat
treatment with long austenitizing time in the furnace reduces the pearlite
ratio, thus enabling a ferritic microstructure to be obtained. In this study,
the ½-inch BSP threading process was applied to materials having both
microstructures after casting and heat treatment. As in the mass production
pipe threading process, fittings were threaded in a multi-threading process
using a universal lathe and in a single threading process using a CNC mill. The
Power Index (PI) was measured during the metal removal process and the energy
consumption of the products was calculated via energy/power conversion
equations. In addition, a new model was proposed that takes into consideration
the energy consumption per product (ECPP) in the mass production machining
process. As a result of combining the energy consumption and energy - power
transformation theory with an experimental investigation, 39% optimization was
achieved. That's a result of this experimental study resulted in energy savings
of 8755 kWh annually.

Keywords

Austenitizing, cast iron, energy consumption, fittings

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