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The potential of reducing the energy consumption for machining TiAl6V4 by using innovative metal cutting processes

: Uhlmann, E.; Fürstmann, P.; Rosenau, B.; Gebhard, S.; Gerstenberger, R.; Müller, G.

Seliger, G. ; TU Berlin, Institut für Werkzeugmaschinen- und Fabrikbetrieb -IWF-; Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik -IPK-, Berlin:
11th Global Conference on Sustainable Manufacturing, GCSM 2013 : Innovative Solutions; 23rd-25th September, 2013, Berlin
Berlin, 2013
ISBN: 978-3-7983-2606-4 (Abstracts)
ISBN: 978-3-7983-2607-1 (CD-ROM)
ISBN: 978-3-7983-2608-8 (CD-ROM)
Global Conference on Sustainable Manufacturing (GCSM) <11, 2013, Berlin>
Fraunhofer IPK ()

Two approaches for energy saving are presented in this paper for turning and milling TiAl6V4 workpieces. The major outcome of the cutting trials with the internally cooled turning tool is that the tool wear under dry cutting conditions is in between dry and wet machining, whereas the combination of the internally cooled turning tool with wet machining leads to strongly increased tool lifetimes. In contrast to this, the energy demand under dry cutting conditions is much lower than under wet cutting conditions. With respect to the environmental protection, the best tool cooling is dry cutting combined with the internally cooled tool. To achieve higher productivity rates or increased tool lifetimes, the combination of wet machining and the internally cooled turning tool is the best solution. In comparison to conventional milling, the average effective power consumption of the machine tool under trochoidal cutting conditions is increased by 6 %. Nevertheless, the amount of used energy is decreased by 15 % and the process time is reduced by 35 %. The reasons for this are higher material removal rates, due to the fact that the cutting time per edge and revolution can be reduced to a minimum. The heat-up phase and the cutting temperatures are small. By increasing the cutting parameters, e. g. cutting speed or feed, it is possible to improve the material removal rate. This enables a higher energy productivity and lower process time. The milling tool was used for both milling strategies. For trochoidal milling the tool has sufficient potential to increase the cutting parameters. For the conventional cutting process, however, the tool works at the load limit.