Resource and Energy Efficiency in Machining Using High-Performance and Hybrid Processes

The main goal in manufacturing is to minimize production time, cost, energy and resources while maintaining or even improving performance. 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 semi-finished 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. (C) 2012 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Konrad Wegener