Abstract:
Manufacturing remains the largest and most important wealth generating sector. Within this sector, material removal is a key technology in the aerospace and automotive industries, contributing to more than $200 billion of the economy in North America on an annual basis. The demand for high productivity and high accuracy is steadily increasing, along with the increasing attention to the impact on the environment. In this work, only conventional machining processes are discussed.
A system approach to the machining system is presented in terms of its elements (machine, tool, workpiece and fixture), properties (materials, configuration, contact interfaces) and interactions (dynamic, tribological, thermal, thermo-elastic) to set the framework for predicting the system response (quality attributes and machining-induced defects) to the operational input. This input describes controlled cutting conditions and uncontrolled dynamic-tribo-thermo-elastic self-induced changes. The impacts of this new approach on the environment will be explored.
The paper provides a critical assessment of the current status of removal technologies of sustainable material. The paper also assesses the research effort towards the development of new and hybrid sustainable machining strategies and processes for: (a) high speed/high performance machining and tool life management, (b) machining of composites and stacked materials, (c) high performance/superabrasive advanced grinding and polishing, and (d) physics-based modeling and simulation of the machining system to achieve a virtual machining environment for the realization of sustainable development philosophy. Life cycle analyses of these technologies, which proved to be effective for applications that involve aggressive metal removal, especially for hard-to-cut materials, are discussed and compared to flood machining. They are compared in terms of their environmental impact on human health, ecosystem quality and natural resources (materials and energy). The effect of MQL and cryogenic machining on the surface integrity of machined surfaces and the reduction in cutting forces, surface roughness and tool wear are presented.
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