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Strategies for Effective Chip Management in Machining of Ductile Cast Iron

Jönsson, Alexander ; Aliboni, Giacomo Carlo Ferdinando LU ; Windmark, Christina LU and Ståhl, Jan Eric LU (2024) 11th Swedish Production Symposium, SPS2024 In Advances in Transdisciplinary Engineering 52. p.50-61
Abstract

A continuously growing and mutating market with increasing demands on environmental sustainability, illuminated by unraveling environmental threats, highlights the need for greater resource efficiency in modern manufacturing industries. Machining has become pivotal in the pursuit of sustainability given its superior efficiency in manufacturing of metallic products. In theory, the efficiency of a machining operation is dictated by the material removal rate and chip formation behavior. However, this may also present additional challenges as chips can be difficult to evacuate from the workpiece, and cause chip carryover. Chip management aims to contain manufacturing costs by addressing this issue and simultaneously pursuing higher... (More)

A continuously growing and mutating market with increasing demands on environmental sustainability, illuminated by unraveling environmental threats, highlights the need for greater resource efficiency in modern manufacturing industries. Machining has become pivotal in the pursuit of sustainability given its superior efficiency in manufacturing of metallic products. In theory, the efficiency of a machining operation is dictated by the material removal rate and chip formation behavior. However, this may also present additional challenges as chips can be difficult to evacuate from the workpiece, and cause chip carryover. Chip management aims to contain manufacturing costs by addressing this issue and simultaneously pursuing higher machining efficiency. Persistent chips trapped in internal cavities is particularly challenging and can affect quality, and result in costly re-manufacturing, scrapping of portions of produced volume. Effective chip management strategies is therefore crucial to avoid these problems. While there is established research on machining theory and chip removal, proposed solutions are often focused on a specific implementation and lack a holistic perspective on the phenomenon. This study aims to fill this gap in the knowledge by providing a strategic and practical application to tie together information that would otherwise be disaggregated. A case study was conducted to investigate the role of machining, and identify the source of chip carryover and its effect on subsequent production stages. Practical verification demonstrated the effectiveness of the proposed interventions in reducing production costs by decreasing the cycle time and reducing waste, and improving product quality. The future of sustainable manufacturing processes relies on the adoption of strategies and interventions that contribute to the efficiency and sustainability of the manufacturing industry. This study provides a valuable contribution to this effort.

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Please use this url to cite or link to this publication:
author
; ; and
organization
publishing date
type
Chapter in Book/Report/Conference proceeding
publication status
published
subject
keywords
Burr Formation, Chip Carryover, Chip Management, Ductile Cast Iron, Metal Cutting
host publication
Proceedings of the 11th Swedish Production Symposium (SPS2024) : Sustainable Production through Advanced Manufacturing, Intelligent Automation and Work Integrated Learning - Sustainable Production through Advanced Manufacturing, Intelligent Automation and Work Integrated Learning
series title
Advances in Transdisciplinary Engineering
editor
Andersson, Joel ; Joshi, Shrikant ; Malmskold, Lennart and Hanning, Fabian
volume
52
pages
12 pages
publisher
IOS Press
conference name
11th Swedish Production Symposium, SPS2024
conference location
Trollhattan, Sweden
conference dates
2024-04-23 - 2024-04-26
external identifiers
  • scopus:85191327728
ISSN
2352-751X
2352-7528
ISBN
978-1-64368-511-3
978-1-64368-510-6
DOI
10.3233/ATDE240153
language
English
LU publication?
yes
id
2b2b0bbc-5e5a-4b10-b8c7-4a559d21a471
date added to LUP
2024-05-07 12:12:10
date last changed
2024-05-21 14:13:14
@inproceedings{2b2b0bbc-5e5a-4b10-b8c7-4a559d21a471,
  abstract     = {{<p>A continuously growing and mutating market with increasing demands on environmental sustainability, illuminated by unraveling environmental threats, highlights the need for greater resource efficiency in modern manufacturing industries. Machining has become pivotal in the pursuit of sustainability given its superior efficiency in manufacturing of metallic products. In theory, the efficiency of a machining operation is dictated by the material removal rate and chip formation behavior. However, this may also present additional challenges as chips can be difficult to evacuate from the workpiece, and cause chip carryover. Chip management aims to contain manufacturing costs by addressing this issue and simultaneously pursuing higher machining efficiency. Persistent chips trapped in internal cavities is particularly challenging and can affect quality, and result in costly re-manufacturing, scrapping of portions of produced volume. Effective chip management strategies is therefore crucial to avoid these problems. While there is established research on machining theory and chip removal, proposed solutions are often focused on a specific implementation and lack a holistic perspective on the phenomenon. This study aims to fill this gap in the knowledge by providing a strategic and practical application to tie together information that would otherwise be disaggregated. A case study was conducted to investigate the role of machining, and identify the source of chip carryover and its effect on subsequent production stages. Practical verification demonstrated the effectiveness of the proposed interventions in reducing production costs by decreasing the cycle time and reducing waste, and improving product quality. The future of sustainable manufacturing processes relies on the adoption of strategies and interventions that contribute to the efficiency and sustainability of the manufacturing industry. This study provides a valuable contribution to this effort.</p>}},
  author       = {{Jönsson, Alexander and Aliboni, Giacomo Carlo Ferdinando and Windmark, Christina and Ståhl, Jan Eric}},
  booktitle    = {{Proceedings of the 11th Swedish Production Symposium (SPS2024) : Sustainable Production through Advanced Manufacturing, Intelligent Automation and Work Integrated Learning}},
  editor       = {{Andersson, Joel and Joshi, Shrikant and Malmskold, Lennart and Hanning, Fabian}},
  isbn         = {{978-1-64368-511-3}},
  issn         = {{2352-751X}},
  keywords     = {{Burr Formation; Chip Carryover; Chip Management; Ductile Cast Iron; Metal Cutting}},
  language     = {{eng}},
  pages        = {{50--61}},
  publisher    = {{IOS Press}},
  series       = {{Advances in Transdisciplinary Engineering}},
  title        = {{Strategies for Effective Chip Management in Machining of Ductile Cast Iron}},
  url          = {{http://dx.doi.org/10.3233/ATDE240153}},
  doi          = {{10.3233/ATDE240153}},
  volume       = {{52}},
  year         = {{2024}},
}