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GB/T 40803-2021: Machining process - Method for energy efficiency evaluation
GB/T 40803-2021
Machining process -- Method for energy efficiency evaluation
ICS 25.020
CCSJ30
National Standards of People's Republic of China
Evaluation method of energy efficiency in machining process
Published on 2021-10-11
2022-05-01 Implementation
State Administration for Market Regulation
Released by the National Standardization Administration
directory
Preface I
1 Scope 1
2 Normative references 1
3 Terms and Definitions 1
4 Evaluation Index System 2
5 Obtaining methods of evaluation indicators 2
6 Evaluation Process and Requirements 4
7 Requirements for the preparation of evaluation reports6
Appendix A (Informative) Example 7 of Energy Efficiency Evaluation in Machining Process
Evaluation method of energy efficiency in machining process
1 Scope
This document specifies the energy efficiency evaluation index system, index acquisition method, evaluation process and evaluation report preparation in machining process.
This document is applicable to the energy efficiency evaluation of metal cutting machine tools. For the energy efficiency evaluation of other machining processes, please refer to this document.
file execution.
2 Normative references
The contents of the following documents constitute essential provisions of this document through normative references in the text. Among them, dated citations
documents, only the version corresponding to that date applies to this document; for undated references, the latest edition (including all amendments) applies to
this document.
GB/T 4863 Basic terms of mechanical manufacturing process
GB/T 6477 Terms of Metal Cutting Machine Tools
GB/T 40799 Basic data detection method of energy efficiency in machining process
3 Terms and Definitions
The terms and definitions defined in GB/T 4863, GB/T 6477 and GB/T 40799 and the following terms and definitions apply to this document.
3.1
specificenergyconsumption
The ratio of the total energy consumption to the effective output of the machining process.
Note. The effective output can be expressed by the material removal volume or the number of qualified workpieces.
3.2
Workpiece specificenergyconsumptionperworkpiece
The ratio of the total energy consumption in the machining process to the number of qualified workpieces.
3.3
specificenergyconsumptionpervolumeofcuttingmaterial
The ratio of the total energy consumption of the machining process to the volume of material removed.
3.4
effectiveenergyutilizationratio
The ratio of the energy consumption for material removal during machining to the total energy consumption for the machining process.
3.5
standbyenergyconsumptionratio
The ratio of the standby energy consumption of the machining process to the total energy consumption of the machining process.
3.6
idlingenergyconsumptionratio
The ratio of the energy consumption of idling in the machining process to the total energy consumption of the machining process.
3.7
cuttingenergyconsumptionratio
The ratio of the cutting energy consumption in the machining process to the total energy consumption in the machining process.
3.8
cutting energyutilizationratio
The ratio of material removal energy consumption to cutting energy consumption during machining.
4 Evaluation index system
4.1 The evaluation index of energy efficiency in machining process includes two types of comprehensive evaluation index and single evaluation index, as shown in Table 1.
4.2 The comprehensive evaluation index is divided into effective energy utilization rate, workpiece specific energy and volume specific energy index, which are mainly used to reflect the comprehensive evaluation of the machining process.
energy efficiency.
4.3 The single evaluation index is divided into standby energy consumption, standby energy consumption rate, idling energy consumption, idling energy consumption rate, cutting energy consumption, cutting energy consumption rate, material
Material removal energy consumption and cutting energy utilization rate are used to reflect the details of the energy efficiency of the machining process.
5 How to get the evaluation index
5.1 Obtaining methods of standby energy consumption, idling energy consumption, cutting energy consumption and material removal energy consumption
Standby energy consumption, idling energy consumption, cutting energy consumption and material removal energy consumption shall be detected and obtained according to the methods specified in GB/T 40799.
5.2 Obtaining method of effective energy utilization
According to the method specified in GB/T 40799, obtain the total energy consumption and material removal energy consumption in the machining process, and calculate the effective energy according to formula (1).
volume utilization.
6.2 Select the machining process to be evaluated
The following two requirements should be met when selecting the machining process to be evaluated.
---The selected processing process belongs to the complete processing process of one or more workpieces processed by the machine tool;
--- The workpieces to be processed have the same specifications.
After the machining process is selected, the processing time period, machine model and workpiece model of the selected machining process should be recorded.
6.3 Selection of evaluation indicators
6.3.1 According to the evaluation requirements, select the energy efficiency evaluation index of the machining process.
6.3.2 To evaluate the comprehensive energy efficiency of the machining process, one or more should be selected from the effective energy utilization rate, workpiece specific energy and volume specific energy.
a comprehensive evaluation index. in.
---Evaluate the overall energy efficiency of different machine tools processing the same workpiece, and give priority to the specific energy of the workpiece;
---Evaluate the overall energy efficiency of the machine tool for processing different materials, and give priority to volume specific energy;
---Evaluate the overall energy efficiency of two machining processes with large differences (for example, machine tools and workpiece specifications are different), and give priority to
Select the effective energy utilization rate.
6.3.3 To evaluate the single-item energy efficiency in the machining process, the single-item evaluation index should be selected according to the following principles.
---Evaluate the energy efficiency of the standby process, and select the standby energy consumption and standby energy consumption rate;
---Evaluate the energy efficiency of the idling process, and select the idling energy consumption and idling energy consumption rate;
---Evaluate the energy efficiency of the cutting process, and select the cutting energy consumption and cutting energy consumption rate;
---Evaluate the selection of cutting parameters in the cutting process, and select the energy consumption for material removal and the utilization rate of cutting energy.
6.4 Establish benchmark values for evaluation indicators
6.4.1 The benchmark value of the evaluation index is the basic reference to quantify the energy efficiency gap and guide the optimization of energy efficiency in the process of energy efficiency evaluation.
According to the data, it can be formulated according to the reference method and the test method.
6.4.2 Reference Statutes. If energy consumption quotas for machining processes and energy efficiency for the same machining processes in the industry have been published
For the advanced value, you can refer to the energy consumption limit standard and the industry advanced value to select the benchmark value for the evaluation index.
6.4.3 Test formulation. The benchmark value of the evaluation index is established through the actual test. Specific steps are as follows.
a) Select a machining process. Among them, the selected machining process should meet the requirements that the machine tool does not fail during the machining process,
The workpieces have the same specifications and are all qualified parts, and the number of qualified parts is not less than 3;
b) According to the method described in Chapter 5, obtain the calculated value of the energy efficiency evaluation index during the processing of each qualified workpiece;
c) Sort the measured values of each evaluation index during the processing of each qualified workpiece in descending order;
d) Select the maximum value in the ranking as the benchmark maximum value of the evaluation index, and select the minimum value in the ranking as the evaluation
The benchmark minimum value for the indicator.
e) For the four indicators of standby energy consumption, idling energy consumption, cutting energy consumption and material removal energy consumption, the benchmark value is the evaluation of a single workpiece.
The product of the benchmark value of the price index and the number of qualified workpieces in the processing process to be evaluated.
See A.3 for specific examples.
6.5 Obtaining the Measured Values of Evaluation Indicators
According to the method specified in Chapter 5, the calculated value of the energy efficiency evaluation index of the machining process is obtained. At the same time, the obtained value of the evaluation index
The extraction process should meet the requirements of GB/T 40799.
6.6 Judging the evaluation results
The calculated value of each evaluation index is compared with its reference value to determine the evaluation result. in.
--- When the calculated value of each evaluation index is lower than its benchmark maximum value and higher than the benchmark minimum value, it is regarded as a normal level.
---For the three indicators of effective energy utilization rate, cutting energy consumption rate and cutting energy utilization rate. when the calculated value is higher than its benchmark maximum
When the value is large, it is regarded as high efficiency; when its measured value is lower than the minimum reference value, it is regarded as low efficiency.
---For workpiece specific energy, volume specific energy, standby energy consumption, standby energy consumption rate, idling energy consumption, idling energy consumption rate, cutting energy consumption and material
These 8 indicators of energy consumption for material removal. when the measured value is higher than its benchmark maximum value, it can be regarded as low efficiency; when its measured value is lower than
When the benchmark minimum value, it can be regarded as high efficiency.
7 Requirements for the preparation of evaluation reports
The evaluation report mainly includes the basic information of the machining process, the energy efficiency evaluation information table and the personnel date information, etc.
as follows.
--- The basic information of the machining process should include the processing time period, machine model and workpiece model.
---The energy efficiency evaluation information table should include evaluation indicators, benchmark values, measured values, evaluation results and suggestions.
--- Personnel date information should include assessor information, reviewer information and assessment date, etc.
See A.6 for an example of an evaluation report.