Open AccessThe paper aim is to develop and study possible energy-efficiency measures for machined forgings drawing on analysis of the impact of the allowance for machining and its scatter.
The most sophisticated option to take into consideration the effect of the cut depth is the work-piece machining in which the forging allowance value results from the blank production.
Research of power consumption was conducted for turning the cylindrical surface of 144 mm length and 1,5 33 0,5 diameter on forgings of the work-pieces "screw of steering control" made from steel 60PP. A radial dimension allowance at said cylindrical surface at six points of the five sections was sized to assess the allowance value dispersion. The size of the sample measurements at the control points was n = 600. Statistic processing has shown normal law of distribution and sample homogeneity.
To analyze the results of experiments was calculated a range of allowances for this workpiece. Calculated minimum and maximum allowance per one side for rough lathing were, respectively, 0.905 mm and 1.905mm. It was found that 77% points under control lie in calculated range of allowance values. And there are no points out of the range on lesser side that proves a lack of rejects; but there are points out of the range on the bigger side, that will require additional costs for machining the specified surface, including the cost of electricity.
There were three power consumption calculations based on factory- recommended duty: for processing the entire sample of forgings with an average allowance, for machining forgings allowances of which are within the recommended design range of allowance, and for processing the entire sample of forgings with a minimum value of allowance.
It was found that elimination of allowance values which are outside the recommended range enables to reduce the power consumption, at least, by 6%, and the overall power consumption for processing the measured forgings exceeds the minimum possible one by 80%.