Efficient utilization of energy is important across all sectors of
industry and economy. Machine tools comprise machines such as the lathe
machine, the drill and sheet metal cutting and bending machines. Energy
utilization varies as the work of the machine progresses. In milling and
drilling operation the spindle or the cutting tool requires much more
energy as the volume of metal being removed increases and subsequently
decreases as the bit approaches the end of the cutting.
Critical Need for Energy Saving In Machining
The overriding importance of energy efficiency and saving is the
overall cost reduction of power requirements. All measures that can
reduce the current drawn by a machine, end up reducing the power
consumption of the machine. Energy efficiency of a machine also
influences the life and the maintenance of the equipment. Energy
efficient machines last longer and have lesser servicing requirements as
compared to others. Currently, lathe and drills machines with geared motors specify the energy efficiency as a marketing strategy.
General Measures for Energy Conservation in the Workshop
Good management of the operation is important for energy efficiency.
Gradual removal of material is more preferred than the sudden removal of
huge volume of metal. This is because it exacts more stress to the
machine than the gradual process.
Operator support during work increases efficiency by reducing time spent in moving the base load.
Energy Demand during Drilling and Milling
Various operating components consume energy during operation. In
lathe operation, processing of the cooling liquid, motor and gears
operation, spindle movement and the logical control units consume power
differently. The greatest consumer however is during machining. Measures
such as efficient lubrication, cooling and accuracy during operation
must be observed to save on energy.
Efficiency of Drive Components
The efficiency of the spindle of the lathe machine is largely
influenced by the ratio of the power consumed versus that of power
delivered. Drive modules, motors, gears and mechanical components
convert the electrical power to mechanical power. Losses occurring due
to frictional losses, poor calibration and wear and tear increase the
cost of operation.
The Introduction of Regenerative Supply Components
The requirement of a braking system is very crucial in every machine
system. When the machine is switched off, all moving parts have a
momentum which must be managed because all that mechanical energy is
converted to electrical energy. Power efficient machines must have a
system to allow for the back EMF to avoid damage to the electrical
components.
Power Consumption in Lathe Machine and sheet metal bending operation
Main energy consuming processes are the rotation and the circulation of the coolant. With the sheet metal bending machine,
the folding process is the heaviest energy consumer. The firmness of
the cutting tool and the accuracy has great bearing on the power
requirements on the drive motor hence the efficiency.
Conclusion
Energy efficiency is a critical requirement while operating machine
tools. Currently, efficiency is one of the key factors considered during
installation of motors. Measures taken to improve efficiency include
adequate lubrication, proper work management, servicing and maintenance
and management of back EMF.
Written by Yash Shah
