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Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling

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Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling University of Nebraska - Lincoln DigitalCommons@University of Nebraska - Lincoln Mechanical (and Materials) Engineering -- Mechanical & Materials Engineering, Dissertations, Theses, and Student Research Department of 12-2012 Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling Matthew S. Kalus University of Nebraska-Lincoln, [email protected] Follow this and additional works at: https://digitalcommons.unl.edu/mechengdiss Part of the Industrial Engineering Commons, Manufacturing Commons, and the Other Mechanical Engineering Commons Kalus, Matthew S., "Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling" (2012). Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research. 43. https://digitalcommons.unl.edu/mechengdiss/43 This Article is brought to you for free and open access by the Mechanical & Materials Engineering, Department of at DigitalCommons@University of Nebraska - Lincoln. It has been accepted for inclusion in Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research by an authorized administrator of DigitalCommons@University of Nebraska - Lincoln. Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling by Matthew S. Kalus A THESIS Presented to the Faculty of The Graduate College at the University of Nebraska In Partial Fulfillment of Requirements For the Degree of Master of Science Major: Mechanical Engineering Under the Supervision of Professor Robert Williams Lincoln, Nebraska December, 2012 Sustainability for Die Manufacturing: Comparative Study of WEDM and Milling Matthew S. Kalus, M.S. University of Nebraska, 2012 Advisor: Robert Williams Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society and a growing population. Thus, concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries (TDMI) are the most well known industries that machine harder materials using mills and wire electrical discharge machines (WEDM). The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute to different effects in the environment, machining performance and operator safety. An experiment was conducted on a Charmilles Robofil 2020 SI WEDM and Bridgeport Milling machine to study the power differences by altering the machines' cutting parameters on a D2 tool steel workpiece. Current, surface roughness, metal removal rates and tool wear were documented. It was noted that increases in power and tool wear can be controlled by varying process parameters such as using cutting fluids and changing the metal removal rate. A higher metal removal rate increased the amount of power used but did not improve surface roughness. Milling and WEDM operations exhibited a similar specific energy trend which is considered another way of comparing both machines. Surface roughness was shown to be better at higher specific energies for WEDM. While in milling, lower surface roughness numbers were seen in a broad range of specific energies. Overall, a correlation between the metal removal rate, power and surface roughness affected sustainability. Other sustainability conclusions compared favorably to the previous literature. An understanding of the differences in these machines is important to determine the best environmentally friendly and cost beneficial setup for any shop. Acknowledgements I would like to give my thanks and gratitude to several people who helped make this thesis possible. First, I would like to thank my advisor, Dr. Robert Williams, for working with me on this project and supplying the resources and guidance throughout its progression. I would also like to thank Dr. Jeffery Shield for helping me analyze the scanning electron microscope photos and Dr. Rajurkar for taking the time to review my paper. Next, I would like to thank the people at the University of Nebraska-Lincoln's Engineering machine shop. Jim McManis and Mark Stroup, in particular, helped me through the setup of the machines. Their help was especially appreciated when the wire EDM machine broke down numerous times. Mark's jokes and company made for an enjoyable experience during the machining. Also, other individuals in the machine shop deserve thanks as well. Mike Long was able to provide good recommendations and advice for some of the machining. David Birdzell measured the wall voltage and was able to attach my power monitor to the machines. The next group of people I would like to thank is my good friends Royce Hocji, Chris Wilson, Josh Rhodig, and Jacob Dow. Royce was able to provide assistance by cutting material apart for me when I was working on a machine. Royce also would bring chocolate covered almonds down to the shop and gladly give them up when I skipped out on lunch. Chris was able to provide a considerable amount of help on the SEM when it came to analyzing the tool wear. Josh Rhodig, my temporary roommate, not only provided his GoPro Hero digital camera, but also, not knowing, provided an ear when I had a lot of complaining to do. Lastly, Jake, one of my good friends from my undergraduate days, let me bounce ideas off of him in the prior stages of the thesis. Lastly, I want to thank my parents, Alfred and Melodian Kalus, for providing the support and guidance through all the rough times not only during the time completing this thesis but throughout my entire college career. i Table of Contents LIST OF FIGURES ............................................................................................. VI LIST OF TABLES .............................................................................................. IX CHAPTER 1 : INTRODUCTION ........................................................................ 1 SECTION 1.1 OBJECTIVE .............................................................................................. 1 SECTION 1.2 BACKGROUND INFORMATION ................................................................. 2 1.2.1 Sustainability and Sustainable Manufacturing ......................................................... 2 Sustainability ....................................................................................................................... 2 Sustainable Manufacturing .................................................................................................. 3 1.2.2 Mill Machining ........................................................................................................ 4 1.2.3 Wire Electric Discharge Machining ......................................................................... 6 1.2.4 Tools and Dies ......................................................................................................... 7 SECTION 1.3 COMPARISON JUSTIFICATION ................................................................ 12 CHAPTER 2 : LITERATURE REVIEW AND PREVIOUS WORK .........................15 SECTION 2.1 OVERVIEW OF LITERATURE REVIEW .................................................... 15 SECTION 2.2 INTRODUCTION TO SUSTAINABLE MANUFACTURING ............................ 15 2.2.1 The Study of Sustainable Manufacturing ............................................................... 15 2.2.2 General Sustainability Costs in Manufacturing ..................................................... 16 SECTION 2.3 POWER CONSUMPTION AND SPECIFIC ENERGY IN MILLING .................. 19 2.3.1 Calculating Theoretical Power Consumption and Specific Energy for Milling .... 19 2.3.2 Power Consumption and Energy Study ................................................................. 22 2.3.3 Power Usage Assessment and Predictions for Milling .......................................... 24 2.3.4 Specific Energy Use and Modeling in Milling ...................................................... 29 SECTION 2.4 WEDM PROCESS PARAMETER STUDIES ............................................... 33 2.4.1 WEDM Power Observations .................................................................................. 33 2.4.3 WEDM Process Parameters on MRR .................................................................... 34 2.4.3 WEDM Current at the Gap .................................................................................... 38 SECTION 2.5 CUTTING FLUIDS AND DIELECTRICS ..................................................... 39 2.5.1 General Cutting Fluid Information ........................................................................ 39 2.5.2 General Dielectric Information .............................................................................. 41 2.5.3 Cutting Fluid and Dielectric Maintenance ............................................................. 42 ii 2.5.4 Environmental and Human Effects ........................................................................ 43 2.5.5 Recycling and Disposal .......................................................................................... 44 2.5.6 Alternative Cutting Fluids ...................................................................................... 47 SECTION 2.6 DRY AND DRYISH MACHINING ............................................................. 48 2.6.1 Dry Machining ......................................................................................................
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