Investigation of the Effects of Austenitizing Heat Treatment on Energy Consumption of Pipe Threading

Energy consumption is an important part of the production cost of mass production industrial enterprises. The casting, heat treatment and threading processes involved in the industrial production of fittings result in high energy consumption. In serial production, the threading of pipe fittings is carried out using high torque and low speed. The thin-walled designs of the fittings lead to rapid cooling, causing the formation of a high rate of pearlite microstructures and subsequent low or extremely hard machinability. Heat treatment with long austenitizing time in the furnace reduces the pearlite ratio, thus enabling a ferritic microstructure to be obtained. In this study, the ½-inch BSP threading process was applied to materials having both microstructures after casting and heat treatment. As in the mass production pipe threading process, fittings were threaded in a multi-threading process using a universal lathe and in a single threading process using a CNC mill. The Power Index (PI) was measured during the metal removal process and the energy consumption of the products was calculated via energy/power conversion equations. In addition, a new model was proposed that takes into consideration the energy consumption per product (ECPP) in the mass production machining process. As a result of combining the energy consumption and energy - power transformation theory with an experimental investigation, 39% optimization was achieved. That's a result of this experimental study resulted in energy savings of 8755 kWh annually.

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