Estudio de la energía específica consumida en el rectificado

Resumen

To contribute in the increase of the productivity and to the energetic saving in companies, the present thesis focuses the investigation on the process of grinding. The energetic efficiency grinding one depends on the suitable selection of different aspects, such as the cutting conditions, the characteristics of the grinding wheel and the material to cut. Consequently, a good indicator to evaluate the energy saving is the estimation of the specific energy consumption SEC. In this study, a strategy is developed to estimate the SEC in the plane surface grinding. This strategy consists on developing a model of the material removal rate Qw, by measuring the power consumption P during grinding of different materials and characterizing the grinding wheel. In particular, this model calculates material removal rate by considering the instantaneous position of the abrasive grains, the cutting parameters and the grain density of the wheel. Finally, the model is developed from the definition of the thickness of chip removed and is compared with other models presented by previous investigations. On the other hand, the experimental measurement of the power consumption by the electric motor is carried out for different cutting conditions and during successive grinding passes. To process the experimental data, subroutines are created that make the interpretation of the results feasible. It is also allow to identify the three phenomena associated to the powers dissipation which characterize this metal cutting process: friction, plastic deformation and chip formation. The grinding wheel topography was measured with laser technology and in the conventional way with diamond cuttings tools, to detached grains and, then measure the average of the grain diameter. Finally, the simulation of the SEC for different depths of cut and feed rate of the piece is carried out. The value obtained from the specific energy consumption in the formation of the chip is similar to that described by other authors, which allows to validate the model and the experiments. The fundamental contribution of this thesis is the development of the mathematical model based on the estimation of the specific energy consumption and that allows to simulate the grinding process. The results obtained with the application of the model have allowed to analyze the correlation between the characteristics of the wheel, the cutting parameters and the behavior of the specific energy consumption. The knowledge of the Qw, will allow to analyze in a future, the flow of heat necessary to harden the piece. This makes it feasible to propose a range of values for the cutting parameters and predict the effects they have on the energy consumption. In addition, obtaining the grinding model for the manufacture of parts, helps to meet the indications on the creation of virtual machines, which proposes the Industry 4.0 philosophy.