A Forging Hardness Dispersion Effect on the Energy Consumption of Machining

• Main Author: L. D. Mal'kova
• Format: Article
• Language: Russian
• Published: MGTU im. N.È. Baumana 2015-01-01
• Series: Nauka i Obrazovanie
• Subjects: energy intensity; energy consumption; dispersion of hardness
• Online Access: http://technomag.edu.ru/jour/article/view/107

<p>The aim of the work is to evaluate a hardness dispersion of forgings to be further machined, and analyse the impact of this dispersion on the resulting power consumption when cutting.</p><p>The paper studies the hardness values of three kinds of parts for automotive manufacturing. Sample of each part was n = 100 pieces. Analysis of measurements showed that 46% - 93% of parts meet requirements for a range defined by the work-piece working drawing. It was found that hardness of one batch of forgings is under dispersion, which distribution is governed by the normal law.</p><p>The work provides calculations for machining the external cylindrical surfaces of the considered parts. In the context of calculating are adopted parameters of the enterprise-processing rate. It is found that power consumption of machining because of the dispersion values of the work-piece hardness is a function of the random BH variable and it itself is a random variable. Two types of samples are considered, namely: the full sample and that of the values that meet requirements for hardness. The coefficient of variation for samples that meet the technical requirements for hardness is lower than for the full samples, so their average value is more reliable characteristic of a set. It was also found that to ensure a reliable prediction of power consumption in designing the manufacturing processes it is necessary to reduce a tolerance range of workpiece hardness to the limit.</p><p>The work gives a comparative evaluation of electric power consumption per unit cylindrical surface of the parts under consideration. A relative change in the electric power consumed at the minimum and maximum levels of the hardness value was introduced as an evaluation criterion. It is found that with changing hardness of machined work-pieces within the tolerance, the change in power consumption in machining the unit surface reaches 16% while in the case its being out of the specified range it does 47%.</p>