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

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

References

1. [1] Weinert, K., Inasaki, I., Sutherland J. W., and Wakabayashi, T., “Dry Machining and Minimum Quantity Lubrication,” CIRP Ann., Vol. 53. No. 2, pp. 511–537, 2004.
2. [2] Düzdar, I., Kantoğlu, B. and Öztürk, B., “A New Product Design after Benchmarking Analysis of Helis Gear Pumps and Optimization in Energy Consumption,” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, Vol. 6, pp. 610-617, 2017.
3. [3] Ingarao, G., Lorenzo D.R. and Micari, F., “Sustainability issues in sheet metal forming processes. An overview,” J. Clean. Prod., Vol. 19, No. 4, pp. 337-347, 2011.
4. [4] Balogun, V.A. and Mativenga, P.T., “Modelling of direct energy requirements in mechanical machining processes,” J. Clean. Prod., Vol. 41, pp. 179-186, 2013.
5. [5] Bhushan, R.K., “Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of Al alloy SiC particle composites,” J. Clean. Prod., Vol. 39, pp. 242-254, 2013.
6. [6] Hanafi, I., Khamlichi, A., Cabrera, F.M., Almansa, E. and Jabbouri, A., “Optimization of cutting conditions for sustainable machining of PEEK-CF30 using TiN tools,” J. Clean. Prod., Vol. 33, pp. 1-9, 2012.
7. [7] Park, C.-W., Kwon, K.-S., Kim, W.-B., Min, B.-K., Park, S.-J., Sung, I.-H., Yoon, W.-S., Lee, K.-S., Lee, J.-H. and Seok, J., “Energy Consumption Reduction Technology in Manufacturing – A Selective Review of Policies, Standards, and Research,” Int. J. Precis. Eng. Man., Vol. 10, No. 5, pp. 151-173, 2009.
8. [8] Akkuş, H , Yaka, H . "Optimization of Turning Process By Using Taguchi Method". Sakarya University Journal of Science 22 (2018): 1444-1448

9. [9] Özsoy, N , Özsoy, M . "Optimization of Surface Roughness of AISI 1040 Stainless Steel in Milling Process Using Taguchi Method". Sakarya University Journal of Science 23 (2019): 113-120
10. [10] Mori, M., Fujishima, M., Inamasu, Y. and Oda, Y., “A study on energy efficiency improvement for machine tools,” CIRP Annals – Manuf. Technol., Vol. 60, pp. 145–148, 2011.
11. [11] Liu, N., Zhang, Y.F. and Lu, W.F., “A hybrid approach to energy consumption modelling based on cutting power: A milling case,” J. Clean. Prod., Vol. 104, pp. 264-272, 2015.
12. [12] Negrete, C.C., “Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA,” J. Clean. Prod., Vol. 53, pp.195-203, 2013.
13. [13] Oda, Y., Mori, M., Ogawa, K., Nishida, S., Fujishima, M. and Kawamura, T., “Study of optimal cutting condition for energy efficiency improvement in ball end milling with tool-workpiece inclination,” CIRP Ann.- Manuf. Techn., Vol. 61, No. 1, pp. 119–122, 2012.
14. [14] Shokoohi, Y., Khosrojerdi, E. and Shiadhi, R., “Machining and ecological effects of a new developed cutting fluid in combination with different cooling techniques on turning operation,” J. Clean. Prod., Vol. 94, pp. 330-339, 2015.
15. [15] Neugebauer, R, Schubert, A., Reichmann, B. and Dix, M., “Influence exerted by tool properties on the energy efficiency during drilling and turning operations,” CIRP J. Manuf. Sci. Technol., Vol. 4, pp. 161–169, 2011.
16. [16] Escalona, P.M., Shokrani, A. and Newman, S.T., “Influence of cutting environments on surface integrity and power consumption of austenitic stainless steel,” Robot. Cim.-Int. Manuf., Vol. 36, pp. 60–69, 2015.
17. [17] Nas, E. and Öztürk, B., “Optimization of surface roughness via the Taguchi method and investigation of energy consumption when milling spheroidal graphite cast iron materials,” Mater. Test., Vol. 60, No. 5, pp. 519-524, 2018.
18. [18] Liu, N., Wang, S.B., Zhang, Y.F. and Lu, W.F., “A novel approach to predicting surface roughness based on specific cutting energy consumption when slot milling Al-7075,” Int. J. Mech. Sci., Vol. 118, pp. 13–20, 2016.
19. [19] Öztürk, B., Küçük Ö., Düzdar, İ. and Altınbilek, Y.S., “Exploring the economical reasons of the usage of unhealthy & low resisting Far-East products in the water pipe systems,” The Turkish Journal of Occupational/Environmental Medicine and Safety, Vol. 2, pp. 60-72, 2017.
20. [20] Öztürk, B., Öktem, H., Said, G., Çetindağ, H.A. and Erzincanlı, F., “Investigation of Cooling Rate on Hardness and Microstructure in Casting Fittings Materials,” in 4th International Symposium on Innovative Technologies in Engineering and Science, ISITES2016, 3-5 November, Alanya/Antalya, Turkey, pp. 1279-1285, 2016.
21. [21] Öktem, H., Öztürk, B. and Akincioğlu, S., “Investigation of energy consumption on thread machining of austempered ductile cast iron materials,” 5th International Conference and Exhibition on Mechanical & Aerospace Engineering, October 02-04, Las Vegas, USA, 2017. DOI: 10.4172/2168-9792-C1-01
22. [22] Korloy, “Korloy cutting tool technical specifications catalogue,” 2018.
23. [23] Fanuc, “Fanuc 1000 CNC user guide,” 2012.
24. [24] Entes, “Entes current transformer and ammeters technical specifications catalogue,” 2018.
25. [25] Shih, M.H., Sung, W.P. & Go, C.G., ‘’ A Design Concept With a DIsplacement Dependent Semi Active Hydraulic Damper Energy Dissipation’’ Exp Tech (2003) 27: 53. https://doi.org/10.1111/j.1747-1567.2003.tb00139.x
26. [26] Virgillito, E., Airale, A.G., Ferraris, A. et al., ‘’Specific Energy Absorption Evaluation on GFRP Laminate Plate by Optical, Thermographic and Tomographic Analysis’’, Exp Tech (2018). https://doi.org/10.1007/s40799-018-0257-y
27. [27] Simić, G., Lučanin, V., Tanasković, J. et al., ‘’ Experimental Research of Characteristics of Shock Absorbers of Impact Energy of Passenger Coaches‘’ Exp Tech (2009) 33