MillingProcessSummary.docVIP

MR 3 Milling Process Unit Process Life Cycle Inventory Dr. Devi Kalla, Dr. Janet Twomey, and Dr. Michael Overcash August 19, 2009 Milling Process Summary 2 Methodology for Unit Process Life Cycle Inventory Model (uplci) 4 Milling Process Energy Characteristics 4 A. Parameters Affecting the Energy Required for Milling 7 Milling Energy 8 Milling time for peripheral milling operation 8 Milling time for face milling operation 9 Idle Energy 13 Basic Energy 14 B. Method of Quantification for Mass Loss 19 Lci for Material Mass Loss Calculations 19 Lci for Cutting Fluid Waste Calculations 19 Lci for Lubricant Oil Waste Calculations 21 Cutting Tool usage 21 Case Study on Milling 21 Product Details: 22 Cutting Parameters 23 Machining Process: 23 Time, Power and Energy calculations 23 Lci Material mass loss calculations 25 Lci for Cutting fluid waste calculations 26 Summary: 26 References Cited 26 Appendices 27 Manufacturers Reference Data 27 Milling Process Summary Milling is a frequent unit process in manufacturing as a mass reduction step, in which a workpiece is fed past a rotating cylindrical tool with multiple cutting edges. The axis of rotation of the cutting tool is perpendicular to the direction of feed. This orientation between the tool axis and the feed direction is one feature that distinguishes milling from drilling. Hence this life cycle heuristic is to establish representative estimates of the energy and mass loss from the milling unit process in the context of manufacturing operations for products. The milling unit process life cycle inventory (uplci) profile is for a high production manufacturing operation, defined as the use of processes that generally have high automation and are at the medium to high throughput production compared to all other machines that perform a similar operation. This is consistent with the life cycle goal of estimating energy use and mass losses representative of efficient product manufacturing. Milling is a cutting process in wh