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In response to the unclear issue of whether the dynamic cutting performance and structural parameters of an industrial hemp blade, which was developed earlier based on the bionic prototype of the batocera horsfieldi, can be optimized in actual working conditions, this paper analyzes the effective clamping conditions of a reciprocating double-acting cutting blade for stalks and the cutting motion. To investigate the effect of different structural and motion parameters, as well as their interactions, of the bionic blade on cutting energy consumption, bionic blades with different combinations of tooth pitch and tooth angle were designed. A Box–Behnken response surface method with three factors and three levels was used to design an experimental scheme. Utilizing rigid-flexible coupling numerical simulation technology, numerical simulation experiments were conducted to investigate the cutting performance of industrial hemp stalks using the blade. A regression model for cutting energy consumption was established, and variance analysis indicated that tooth angle, speed ratio, and the interaction between tooth angle and speed ratio had an extremely significant effect on the regression model. The primary and secondary orders of factors affecting cutting energy consumption were determined to be: speed ratio > tooth angle > tooth pitch. Through optimization, the optimal parameter combination was found to be a blade tooth pitch of 6.61 mm, a tooth angle of 30°, and a speed ratio of 1.62. Under these conditions, the cutting energy consumption was 3947.99 mJ. The optimized parameters were verified through numerical simulation cutting experiments, and the results showed that the error compared with the optimization results was only 8.16%. This indicates that the optimization results have high credibility and further verifies the reliability of the model. This study can provide a reference for the development of cutting devices for industrial hemp harvesters and the selection of motion parameters. [ABSTRACT FROM AUTHOR]

As an indispensable piece of equipment in the manufacturing industry, the machine tool is low-energy-efficiency and high-energy-consumption in operation. Therefore, it is urgent to establish a cutting energy consumption model to guide production and reduce the energy consumption of the machining process. In this paper, the AlTiCrN-coated cutting tool is taken as the object of study, and the cutting energy consumption model is established. The cutting energy consumption model is composed of a machining time model and a cutting power model. The cutting power model can be divided into the shear deformation power model of the workpiece, the friction power model of the flank surface and the friction power model of the rake surface. The influence of the edge shape is taken into account in the establishment of the friction power model of the flank surface. The machining time model considering the S-type acceleration and deceleration stage is established. The accuracy of the model was verified by experiments. Experimental results show that the model has high accuracy. The Taguchi method was used to carry out the numerical experiment with the cutting energy consumption of the machine tool as the response. The influences of cutting parameters on energy consumption are analyzed. Cutting width is the most important factor, followed by cutting depth, then feed rate and spindle speed. The physical principle of the influence of cutting parameters on cutting energy consumption is revealed. [ABSTRACT FROM AUTHOR]

Caragana korshinskii (C.K.) flat stubble residue is an abundant biomass energy source in China. Because branch cutting is closely related to the harvesting of forest biomass, it is practical for forestry production and ecological development to investigate the effects of cutting parameters on the peak cutting force and cutting energy consumption of C.K. branches. In this study, the effect of cutting parameters on the peak cutting force and cutting power consumption of branches was investigated by single-factor and multi-factor tests using an independently developed reciprocating cutting test bench, and an optimization model was established. The interaction term of average cutting speed and tool cutting edge inclination angle significantly affected the peak cutting force, while the interaction term of cutting clearance and wedge angle had a significant effect on the cutting energy consumption. The optimal combination of cutting parameters was an average cutting speed of 0.5 m/s, cutting clearance of 1.4 mm, wedge angle of 25°, and tool cutting edge inclination angle of 20°. With this combination of parameters, the corresponding peak cutting force was 644.38 N, and the cutting energy consumption was 5.90 J, which was less than 5% relative error between each performance index and the theoretical optimized value.

In order to solve the problems of low accuracy and large loss of heading equipment in cutting trajectory planning method of roadheader, a cutting trajectory planning method of roadheader based on hybrid IWO (invasive weed optimization)-PSO (particle swarm optimization) algorithm is proposed. The cutting section environments are divided into three types, namely single gangue, double gangue and multi-gangue, and the corresponding sections are rasterized and the grid map is established. The irregular gangue is expanded by using binary expansion method. The hybrid IWO-PSO algorithm is used for trajectory planning in the three types of section environments. The hybrid IWO-PSO algorithm is based on the seed diffusion method in IWO algorithm, which diffuses the initial population and allows all individuals to reproduce freely before competitive exclusion, thus effectively ensuring the diversity of optimization space. The position iterative update method in PSO algorithm is also used to iteratively update the reproduced seed positions, and the particle positions are adjusted in time by using group experience and individual experience to improve the optimization depth and speed of the algorithm effectively. The simulation results show that the length of cutting trajectory, the number of secondary excavation grids and the cutting energy consumption of the roadheader based on the hybrid IWO-PSO algorithm are smaller than those of the standard PSO algorithm, and the capability to avoid the obstacle and gangue is better than that of the standard PSO algorithm. The section cutting test is carried out by EBZ135 roadheader, and the results show that the maximum errors of the left side, right side and both sides of the roadway section forming are 30, 20 and 50 mm respectively, and the relative error is within 2%, 1.4% and 1.7% respectively, which can meet the requirements of effective obstacle avoidance and forming under different roadway section environments.

In response to the unclear issue of whether the dynamic cutting performance and structural parameters of an industrial hemp blade, which was developed earlier based on the bionic prototype of the batocera horsfieldi, can be optimized in actual working conditions, this paper analyzes the effective clamping conditions of a reciprocating double-acting cutting blade for stalks and the cutting motion. To investigate the effect of different structural and motion parameters, as well as their interactions, of the bionic blade on cutting energy consumption, bionic blades with different combinations of tooth pitch and tooth angle were designed. A Box–Behnken response surface method with three factors and three levels was used to design an experimental scheme. Utilizing rigid-flexible coupling numerical simulation technology, numerical simulation experiments were conducted to investigate the cutting performance of industrial hemp stalks using the blade. A regression model for cutting energy consumption was established, and variance analysis indicated that tooth angle, speed ratio, and the interaction between tooth angle and speed ratio had an extremely significant effect on the regression model. The primary and secondary orders of factors affecting cutting energy consumption were determined to be: speed ratio > tooth angle > tooth pitch. Through optimization, the optimal parameter combination was found to be a blade tooth pitch of 6.61 mm, a tooth angle of 30°, and a speed ratio of 1.62. Under these conditions, the cutting energy consumption was 3947.99 mJ. The optimized parameters were verified through numerical simulation cutting experiments, and the results showed that the error compared with the optimization results was only 8.16%. This indicates that the optimization results have high credibility and further verifies the reliability of the model. This study can provide a reference for the development of cutting devices for industrial hemp harvesters and the selection of motion parameters.

In order to improve the energy utilization rate and to reduce the energy consumption in the machining process of wood plastic composites (WPC), the influence relation among cutting parameters, cutting power and energy consumption is analyzed. The energy consumption of WPC in the milling process is studied in this article. The energy consumption model of the motor in the cutting process is established, and the trend of change on energy consumption of machine tool quantitatively divided into eight characteristic stages. The influence of different cutting parameters and milling methods on cutting energy consumption and cutting energy consumption per unit volume shows that feed rate, cutting speed, cutting width and cutting power feed rate, cutting speed, cutting width and cutting power change direct proportional. Feed rate, cutting width and cutting energy consumption per unit volume Feed rate, cutting width and cutting energy consumption per unit volume change inversely proportional. The change rule of cutting energy consumption of WPC is exposed. The theoretical prediction model of energy consumption is established based on the experimental data, which provides a scientific basis to realize the green processing of WPC with high efficiency and low energy consumption. [ABSTRACT FROM AUTHOR]

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In order to study the cutting energy consumption characteristics of coal miner under complicated conditions, the MG500/1180-WD shearer was cut out under different working conditions by collecting the cutting energy consumption model of coal mining machine. Pin and idler axle load data, and finally through the different conditions of coal miners cutting energy consumption calculation, the following conclusions: to keep the other conditions remain unchanged, the linear cutting energy consumption with With the increase of the traction speed increase; the oblique cut cutting energy consumption value is far more than the straight cutting energy consumption value; shearer cutting energy consumption in addition to the speed of traction, cutting mode, but also by the impact of coal hardness, With the increase in the hardness of coal and cutting cutting energy consumption also increased. The results of this study provide the theoretical basis for the development and use of shearer, and provide the theoretical basis for the scientific and efficient production of coal mining industry.

Cutter design and multi-objective optimization of machine for cable peeling is proposed to use mechanical peeling instead of manual peeling in this paper. First, the design of the machine for cable peeling includes executive mechanism, driving part for cable, driving part for executive mechanism, and peeling mechanism. Then, the cutting experiment platform is set up to verify the actual effect of cutting, and different cutting depths, cutting speeds and fixing cables methods are discussed by the cutting experiment platform. A numerical simulation method is proposed, and different cutting methods, cutting depths and cutting speeds for cutting different materials are discussed by simulation method. The results show that simultaneous cutting is better than sequential cutting. The results show a good agreement between the results obtained from the finite element modelling and experimental investigations. A theoretical reference is provided for subsequent structural improvement. Finally, multi-objective optimization of machine for cable peeling is realized. The aim of the optimization was improving the dimensional accuracy after cutting and reducing the deformation of the cut surface. Cutter thickness, cutter angle, and cutter material are used as optimization variables, and the final optimal solution is obtained. The cutter is manufactured according to the final optimal solution, experiment of cutting is performed, and good agreements were achieved between optimal solution and experiments. Comparing the final results with the initial results shows a significant improvement.

The high energy consumption and low crushing length qualification rate of traditional straw returning machines in the main maize-growing regions of northeast China make it difficult to promote straw returning operations in the region. The primnoa locust mouthpart is extremely efficient in cutting maize rootstocks. In this paper, it was found that there are significant differences between the primnoa locust mouthpart and the conventional machine, these exist mainly in the cutting edge structure and cutting motion. Thus, this paper develops a coupled bionic design for structural and kinematic coupling elements to develop a bionic straw returning machine. This paper found that the operating performance of the bionic straw returning machine was mainly affected by the blade rotation radius and the output rotation speed of the drive mechanism through DEM (discrete element method) simulation, and the optimal combination of the two parameters was 248 mm rotation radius and 930 r/min output rotation speed. Finally, this paper finds that the most obvious operational performance difference of the bionic straw returning machine compared with the traditional straw returning machine is that it can reduce the cutting power consumption by 9.4–11.7% and improve the crushing length qualification rate by 10.4–14.7% through the operational performance comparison test. Based on the above findings, this paper suggests that in future research and development of straw returning machines, more attention can be focused on finding suitable bionic prototypes and improving bionic design methods.

Targeting energy-efficient machining process planning, this paper presents a follow-up research on cutting energy consumption modelling for prismatic machining features (PMFs). Based on the investigation of plastic deformation-based energy consumption, its energy consumption model is extended to PMFs by refining machining time and feed at corners. Material removal volume associated with machining strategies for the PMF machining is considered as well. Moreover, cutting energy consumption models are established for the selected PMFs, i.e. face, step, slot and pocket. Finally, energy consumptions in machining of a designed test part, involving the established models of cutting energy consumption for the selected PMFs, are measured and compared with estimated energy consumptions to validate the developed models. [ABSTRACT FROM AUTHOR]

The energy consumption of numerical control (NC) machine tools is mainly from the cutting process. Since the cutting process has multiple characteristics, such as nonlinear, multi-variable and time-varying characteristics, it is difficult to establish an accurate model of the cutting energy consumption by both the static modeling and the traditional mechanism modeling. In this paper, the unscented Kalman filter neural network (UKFNN) is proposed to model the cutting energy consumption of NC machine tools. In the resulting model, the unscented Kalman filter (UKF) is adopted to update weights and thresholds of the neural network in real time, improving the generalization ability and the accuracy of the model. Experimental results show that the proposed method is effective and reliable to model the cutting energy consumption of NC machine tools. [ABSTRACT FROM AUTHOR]

Energy saving and surface quality are priorities in manufacturing industry with increased sustainability and high-quality consciousness. This paper presents a cooperative optimization approach to choose optimal cutting parameters for energy saving and quality assurance considering the effects of tool wear and cutting parameter combinations at a certain material removal rate. Cutting energy consumption, energy efficiency and surface roughness are optimization objectives and their functions are developed with cutting parameters and tool wear. The multi-objective optimization model is constructed with constraints and solved by NSGA-III. A turning application case is given and the results illustrate the effectiveness of the proposed method. [ABSTRACT FROM AUTHOR]

The significance of the study is that the analysis of cutting performance and parameter optimization of the disc cutter can effectively improve the service life of the tool and reduce the cutting energy consumption. The method of the study is as follows: The numerical model based on the discrete element method was developed for rock cutting. The validation experiment was carried out to prove the reliability of the numerical model. The effect of swing arm speed, spindle speed and cutting depth on the wear, cutting specific energy and broken rock volume of the disc cutter was analyzed. The prediction models of cutting wear and cutting specific energy were established based on the response surface method, and the parameters were optimized. The validation experiment was carried out with the obtained optimal parameters as experimental conditions. The experiment verifies the reliability of the disc cutter wear and energy consumption optimization models. The conclusion is as follows: The cutting depth has the greatest effect on the wear of the disc cutter, followed by the spindle speed, while the swing arm speed has the least effect on the wear of the disc cutter. With the increase of the swing arm speed and cutting depth, the wear of the disc cutter increases. The maximum cutting wear can reach 4.75 mm and 5.03 mm. The average cutting wear can reach 2.57 mm and 2.29 mm. With the decrease of the spindle speed, the wear of the disc cutter increases, and the maximum wear and average wear can reach 4.71 mm and 2.30 mm. The increase of swing arm speed and cutting depth can improve cutting efficiency, but excessive swing arm speed and cutting depth will increase the wear and reduce the tool life. The swing arm speed has the greatest influence on the cutting specific energy, followed by the spindle speed, while the cutting depth has the least influence on the cutting specific energy. As the swing arm speed increases, the energy consumption of cutting becomes larger. The increase of the swing arm speed can improve the cutting efficiency, but the excessive swing arm speed will increase the energy consumption. With the increase of spindle speed, the rock cutting efficiency of the disc cutter becomes larger, and the energy consumption first decreases and then increases. Too small spindle speed will aggravate the energy consumption. The maximum cutting specific energy can reach 29.85 MJ/m3. When the swing arm speed v = 5 mm/s, the spindle speed n = 99 r/min and the cutting depth h = 14 mm, the wear and energy consumption of the disc cutter are minimal at the same time, which shows that the cutting performance of the disc cutter is better. The average wear and cutting specific energy of the disc cutter after parameter optimization are 1.64 mm and 17.59 MJ/m3, respectively. The conclusion of the study is that the experiments have verified the reliability of the discrete element disc cutter rock cutting analysis model, which can simulate the disc cutter cutting process more accurately. The optimization model is reliable, and the wear and energy consumption of the disc cutter are minimal at the same time after the optimization analysis, which provides a theoretical reference for improving the service life of the disc cutter and reducing the cutting energy consumption. [Display omitted] [ABSTRACT FROM AUTHOR]

Abstract: Inability of machining steel strongly inhibits the application of diamond machining in manufacturing industry, especially in the fields of ultra-precision and micro machining. In recent years, vibration-assisted machining (VAM) has been proved to be capable of efficiently suppressing the diamond tool wear in cutting steel. Currently, the prevailing speculation claimed by most researchers for such suppression is that the tool–workpiece flash temperature was reduced in VAM, which would slow the chemical reaction between iron on steel and carbon on diamond. However, the correctness of this speculation has not been proved by any experimental or theoretical research. In this paper, in order to understand the true wear suppression mechanism of diamond tools in VAM of steel, a study is conducted by measuring the workpiece temperatures and modeling the cutting energy consumption in both VAM and conventional cutting (CC). Based on the comparison results, it is concluded that the cutting temperature and energy consumption in VAM are not smaller than in CC, and hence the reduced diamond tool wear in VAM should not be caused by the claimed reduced temperature, especially when the material removal rate is very small. Finally, based on the EDS analysis and the comparison of experimental results under different air pressure, two probable reasons are proposed for the significantly reduced diamond tool wear in VAM of steel: (i) increase of gas pressure at the tool–workpiece interface and (ii) generation of an oxide layer on the freshly machined surface. [Copyright &y& Elsevier]

The high energy consumption and low crushing length qualification rate of traditional straw returning machines in the main maize-growing regions of northeast China make it difficult to promote straw returning operations in the region. The primnoa locust mouthpart is extremely efficient in cutting maize rootstocks. In this paper, it was found that there are significant differences between the primnoa locust mouthpart and the conventional machine, these exist mainly in the cutting edge structure and cutting motion. Thus, this paper develops a coupled bionic design for structural and kinematic coupling elements to develop a bionic straw returning machine. This paper found that the operating performance of the bionic straw returning machine was mainly affected by the blade rotation radius and the output rotation speed of the drive mechanism through DEM (discrete element method) simulation, and the optimal combination of the two parameters was 248 mm rotation radius and 930 r/min output rotation speed. Finally, this paper finds that the most obvious operational performance difference of the bionic straw returning machine compared with the traditional straw returning machine is that it can reduce the cutting power consumption by 9.4–11.7% and improve the crushing length qualification rate by 10.4–14.7% through the operational performance comparison test. Based on the above findings, this paper suggests that in future research and development of straw returning machines, more attention can be focused on finding suitable bionic prototypes and improving bionic design methods. [ABSTRACT FROM AUTHOR]