The deflections of screw rotors under machining forces cause mismatch between the male and female rotors and, consequently, accelerated wear and suboptimal efficiency in their performance. Optimizing the machining process to minimize the generated forces and accounting for the resulting mismatch in the design of the rotor profile requires accurately computing the machining forces in computer simulations. Virtual machining systems combine graphics-based computation of the Cutter-Workpiece Engagement (CWE) with the physics-based models of machining mechanics to simulate the forces during complex machining processes. However, because of the high computational load of graphical simulations, virtual machining is not suitable for the repetitive force simulations that are required for optimizing the design and manufacturing of rotors. In this work, we present a new method that simulates screw milling forces based on the process kinematics instead of graphical simulations. Utilizing mathematical equations that describe the process kinematics, the theoretical rotor profile is determined for feasible combinations of cutting tool profile, setup angle, and centre distance. Subsequently, to find the milling forces, the cutting edge is discretized into multiple small edge segments and a mechanistic cutting force model is used to determine the local cutting forces at each segment. After geometric and kinematic transformations of these local forces, the screw milling forces are obtained for each roughing and finishing pass. Instead of graphics-based methods, the engagement conditions between the cutter and workpiece are determined by the ensemble of 2D rotor and tool profiles; as a result, the computational efficiency is increased substantially. The semi-analytical nature of the presented method allows for computing the forces with arbitrary resolution within a reasonable time. The accuracy and efficiency of the presented method is verified by comparing the simulated forces against a dexel-based virtual machining system. / Graduate

<div>The purpose of this research is to analyze the overall energy consumption of an industrial compressed air system, and identify the impact of various energy saving of individual subsystem on the overall system. Two parameters are introduced for energy consumption evaluation and potential energy saving: energy efficiency (e) and process effectiveness (n). An analytical energy model for air compression of the overall system was created taking into consideration the modeling of individual sub-system components: air compressor, after-cooler, filter, dryer and receiver. The analytical energy model for each subsystem included energy consumption evolution using the</div><div>theoretical thermodynamic approach. Furthermore, pressure loss models of individual components along with pipe friction loss were included in the system overall efficiency calculation.</div><div>The efficiency analysis methods and effectiveness approach discussed in this study were used to optimize energy consumption and quantify energy savings. The method</div><div>was tested through a case study on a plant of a die-casting manufacturing company. The experimental system efficiency was 76.2% vs. 89.3% theoretical efficiency. This showed model uncertainty at ~15%. The effectiveness of reducing the set pressure increases as the difference in pressure increase. The effectiveness of using outside air for</div><div>compressors intake is close to the compressors work reduction percentage. However, it becomes more effective when the temperature difference increase. This is mainly due to extra heat loss. There is potential room of improvement of the various component using the efficiency and effectiveness methods. These components include compressor, intercooler and dryer. Temperature is a crucial parameter that determines the energy consumption applied by these components. If optimum temperature can be determined, plenty of energy savings will be realized.</div>