Energy Efficient Cleaning and Dry Machining

approach_b2Turning trials with and without cutting lubricant were undertaken with the internally-cooled turning tool. The cutting tool is worn after a few minutes when titanium is machined without any tool cooling. Whereas, turning with cooling lubricant and internally-cooled tool reduces wear significantly. The end of tool life was reached after one hour, instead of four minutes for dry cutting without any cooling. When comparing the amount of energy for tool cooling and the amount of energy for tool manufacturing, it became clear that dry machining with the internally-cooled tool is having the lowest energy consumption of all tested cooling methods. The major benefit of dry cutting with the internally-cooled tool is the prevention of deceases caused by cooling lubricants and environmental pollution.

In general, cleaning processes are based on a combination of different cleaning mechanisms. A dishwasher for example, combines a chemical effect of a detergent with the thermal and mechanical effect of the heated water, which is sprayed upon the dishes. The cleaning mechanisms’ efficient combination of dry ice blasting is investigated in subproject B2.
The Identification of an application specific combination of the blasting particles’ mechanical impact and the thermal effect of the particles will help to reduce electricity and carbon dioxide consumption. The conventional acceleration by compressed air shell be substituted by a rotational wheel based mechanical acceleration. Due to this, detailed knowledge of the particle impact is needed to avoid early sublimation losses of wheel blasting with dry ice: Conventional wheel blasting devices are not suitable for non-durable blasting media. At the same time, the investigation of the particle impact led to the development of a new blasting benchmark, which does not depend on the blasting target, e. g. the specific material removal rate.
Learn more about challenges, approach and results of project B2 in this Powerpoint presentation