Publication: Cutting design for oil palm frond analysis of circular saw
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Date
2024-08-01
Authors
Sun, Qun
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Abstract
This study develop a model to assess energy consumption, cutting force associated with the use of
circular saw in the cutting of oil palm fronds. The energy consumption model is formulated based on
kinematic equations and a simplified cutting process model, incorporating Ernst and Merchant's
force circle. The final cutting power equation considers sawing and clamping, dependent on circular
saw geometry, tooth shear angle, disc thickness, feed rate, speed, frond rupture modulus, and
friction coefficient between the saw and frond. This model is validated against experimental
data (38<F<145, 0.72<R2<0.91, P<0.05). Determining the power consumption of cutting oil palm fronds
with circular saws is crucial for economic efficiency. Developing a specific power consumption
model can reduce cutting force and improve efficiency. Circular saws also generate vibration and
noise, so cutting technology must reduce noise levels to acceptable standards. The validated
equation is used to optimize the cutting process, achieving a minimum cutting energy of 330J at
1000 rpm and a feed rate of 10 mm/s. Regression equations developed with these variables show a
high correlation (p < 0.05, R2 = 0.987, AdjR2 = 0.95). Optimal cutting parameters for reducing
cutting forces are a rotation speed of 2000 rpm, entrance angle of 0°, and a feed rate not
exceeding 10 mm/s. The EMS method and FEA are used to quantify noise reduction and structural
reliability. Results show that an L-slot with a
40mm radial length and 15mm circumferential length decreases impact vibration amplitude by 53.27%
and vibration attenuation time by 25% compared to a 20mm radial length and 15mm circumferential
length. The sound pressure level decreases from 57 dB to 52 dB, validating the proposed technology.