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Research Papers

Determination of Shape and Distribution of Abrasive Grains to Reduce Carbon Emissions of Honing Process

[+] Author and Article Information
Qi Lu

School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China
e-mail: luqi1234@stu.xjtu.edu.cn

Guang-Hui Zhou

State Key Laboratory for Manufacturing
Systems Engineering,
School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China
e-mail: ghzhou@mail.xjtu.edu.cn

Fu Zhao

Environmental and Ecological Engineering,
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu

Lei Li

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com

Ya-Ping Ren

School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: renyp1@163.com

1Corresponding author.

Manuscript received April 24, 2018; final manuscript received September 11, 2018; published online December 24, 2018. Assoc. Editor: Karl R. Haapala.

J. Manuf. Sci. Eng 141(2), 021008 (Dec 24, 2018) (14 pages) Paper No: MANU-18-1271; doi: 10.1115/1.4041481 History: Received April 24, 2018; Revised September 11, 2018

Due to the increasing concern on environmental sustainability, many efforts have been made to improve the energy efficiency and reduce carbon emissions of manufacturing processes, including abrasive machining processes. Oilstones, as the abrasive tool of honing machines, are the key parts to remove material. However, the theoretical models and methods that can be used to support the selection of oilstone parameters for reduced carbon emissions are lacking. To fill this gap, this paper proposes a method to optimize shape and distribution of abrasive grains for minimized carbon emissions while maintaining surface quality. First, the carbon emissions boundary is defined, and a carbon emissions calculation model is established from a macroperspective. As each grain contributes to the total carbon emissions, the behavior of grains during honing is then described and analyzed to obtain the carbon emissions model from a microperspective. Surface area of oilstones and the required total volume of material removal are kept constant to meet the physical size limit of oilstones and machining requirement of workpiece. Third, a shape and distribution optimization model is developed to minimize carbon emissions. A modified particle swarm optimization (PSO) algorithm is adopted to solve this problem. Finally, the proposed method is applied to a case study to validate its effectiveness. Results show that carbon emissions can be reduced by up to 30% using the proposed model. The proposed method provides a new green manufacturing strategy for the honing process and a possibility to customize abrasive tools to meet the environmental challenges.

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Figures

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Fig. 1

Carbon emissions boundary

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Fig. 2

Illustration of a honing process

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Fig. 3

Schematic of abrasive grains position before and after cutting

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Fig. 4

Calculation steps of the projection area of grains

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Fig. 5

Schematic diagram of the new coordinate system

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Fig. 6

Schematic diagram of overlapping and nonoverlapping conditions

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Fig. 7

The diagram of the initial population

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Fig. 8

Evolution process of the fitness function: (a) evolution process of the average fitness and (b) evolution process of the best fitness

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Fig. 9

Location and force distribution of grains

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Fig. 10

Optimal parameters and topography of grains

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Fig. 11

Correlation between carbon emissions and the number of grains

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Fig. 12

Distribution and carbon emissions of grains

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Fig. 13

Correlation between the shape angles and carbon emissions

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Fig. 14

Condition 1: shape and distribution scheme of grains

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Fig. 15

Carbon emissions under condition 1 and condition 2

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