Abstract
Machine tools, as the extensively used basic equipment of manufacturing industry, are characterized by intensive and inefficient energy consumption. With the launch and implementation of ISO 14955-1, energy efficiency has become an important criterion for machine tool evaluation. However, most ongoing research on energy efficiency evaluation of machine tools emphasizes on workpiece material removal energy efficiency and rarely considers energy consumption needed to ensure machining accuracy and accuracy consistency, especially energy consumption for thermal stability control of machine tools. In light of this, an exergy analysis based approach is presented to assess the comprehensive energy efficiency of machine tools, including energy consumption for material removal and thermal stability control. The key performance indexes of exergy efficiency, exergy destruction, and specific exergy consumption are analyzed. The feasibility of the proposed approach was demonstrated by a case study, in which the comprehensive energy efficiency of a machine tool was found to be 21.57% instead of 14.38% of material removal energy efficiency. The proposed method is more effective to evaluate the comprehensive energy efficiency, to support designers to design high-efficient machine tool and users to operate machine tool for green and precision machining.
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Abbreviations
- A surf :
-
surface area of machine tool shell
- A nc :
-
The area of natural heat convection
- c ho :
-
Specific heat of hydraulic oil
- c co :
-
Specific heat of cooling fluid
- c lu :
-
Specific heat of lubricant
- c ca :
-
Specific heat of compressed air
- ca :
-
Specific heat capacity of air
- E elec,MT :
-
Electrical energy input of machine tool drives
- E elec,PD :
-
Electrical energy input of peripheral devices
- E MR :
-
Material removal energy
- E loss :
-
Electrical energy loss
- Ėx dest :
-
Exergy destruction rate
- Ėx elec,MT :
-
Electrical exergy rate of machine tool drives
- Ėx elec,PD :
-
Electrical exergy rate of peripheral devices
- Ėx MR :
-
Material removal exergy rate
- Ėx mass,ca :
-
Flow exergy rate of compressed air
- Ėx mass,co :
-
Flow exergy rate of coolant
- Ėx mass,ha :
-
Flow exergy rate of hot air
- Ėx mass,ho :
-
Flow exergy rate of hydraulic oil
- Ėx mass,lu :
-
Flow exergy rate of lubricant
- Ėx nc :
-
Thermal exergy output rate of heat transfer by natural convection
- h nc :
-
Convection heat transfer coefficient
- ṁ ca :
-
Mass low rate of compressed air
- ṁ co :
-
Mass low rate of cooling fluid
- ṁ ha :
-
Mass low rate of hot air
- ṁ ho :
-
Mass low rate of hydraulic oil
- ṁ lu :
-
Mass low rate of lubricant
- P elec,feed :
-
Electrical power input of feed motor
- P elec,sp :
-
Electrical power input of spindle
- p 0 :
-
Ambient air pressure
- p ca :
-
Compressed air pressure
- Q̇ hr :
-
Heat transfer rate of radiation
- Q̇ nc :
-
Heat transfer rate of natural convection
- R g :
-
Gas constant
- T 0 :
-
Ambient air temperature
- T ca :
-
Temperature of compressed air
- T co :
-
Temperature of cooling fluid
- T ha :
-
Temperature of hot air
- T ho :
-
Temperature of hydraulic oil
- T lu :
-
Temperature of lubricant
- T surf :
-
Average temperature of machine tool surface
- y PD :
-
Exergy destruction ratio of the kth peripheral device
- y MT :
-
Exergy destruction ratio of machine tool drives
- ε surf :
-
Emissivity of machine tool shell
- ε PD :
-
Exergy efficiency of peripheral device
- ε MT :
-
Exergy efficiency of machine tool drives
- ε tot :
-
Total exergy efficiency
- σ :
-
Stefan–Boltzmann constant
- η I :
-
Traditional energy efficiency
- η II :
-
Comprehensive energy efficiency
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Acknowledgements
This work was supported by the National Natural Science Foundation of China (Grant number 51975076); the National Key Research and Development Program of China (Grant number 2018YFB2002201); the Project of International Cooperation and Exchanges NSFC (Grant number 51861165202); and the Fundamental Research Funds for the Central Universities of China (Grant number 2018CDJDC0001). The authors gratefully acknowledge the reviewers and editors for their insightful comments.
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Li, B., Cao, H., Hon, B. et al. Exergy-based Energy Efficiency Evaluation Model for Machine Tools Considering Thermal Stability. Int. J. of Precis. Eng. and Manuf.-Green Tech. 8, 423–434 (2021). https://doi.org/10.1007/s40684-020-00204-8
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DOI: https://doi.org/10.1007/s40684-020-00204-8