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Resource and energy efficiency in machining using high-performance and hybrid processes

: Neugebauer, Reimund; Drossel, Welf-Guntram; Wertheim, Rafael; Hochmuth, Carsten; Rennau, Anett; Dix, Martin


Wegener, K. ; TH Zürich -ETH-, Institut für Werkzeugmaschinen und Fertigung -IWF-; International Academy for Production Engineering -CIRP-, Paris:
5th CIRP Conference on High Performance Cutting 2012 : 4.-7. June 2012, Zürich; HPC 2012
Amsterdam: Elsevier, 2012 (Procedia CIRP 1.2012)
Conference on High Performance Cutting (HPC) <5, 2012, Zürich>
Fraunhofer IWU ()
flushing; hybrid; resource; energy efficiency

The main goal in manufacturing is to minimize production time, cost, energy and resources while maintaining or even improvingperformance. The main influence on process efficiency in metal cutting can be related to the machining parameters, while performance also depends on the material behavior such as strain rate, machining temperature and cutting forces. In the past, industry was searching for higher efficiency mainly by using higher production rates, achieved with higher cutting conditions. However, during the last decade the production process chain has been controlled more and more by the near-net-shape of semifinished components and the use of high performance processes. This paper presents established and new applications of process modifications, substitutions, optimizations as well as the use of hybrid processes. In high performance cutting (HPC) additional elements play an important role, for example tool design and tool material, wear and tool life, coolant strategies, including dry cutting, MQL, cryogenic and high pressure flushing as well as the machine tool properties. Furthermore, this paper presents and discusses examples of the influence of process parameters in turning, milling, drilling, grinding and impact cutting under HPC conditions on the energy and resources efficiency in the automotive, aerospace, dies and moulds, micromachining and heavy duty industries.