A mechanistic model of energy consumption in milling

Abstract

In this paper, a novel mechanistic model is proposed and validated for the consumption of energy in milling processes. The milling machine is considered as a thermodynamic system. Mechanisms of the significant energy conversion processes within the system are used to construct an explicit expression for the power consumption of the machine as a function of the cutting parameters. This model has been validated experimentally and is shown to be significantly more accurate than popular existing models. A simplified form of the model is also proposed that provides a balance between complexity and accuracy. The novelty of the model is that it maps the flow of energy within a machine tool, based solely on the active mechanisms of energy conversion. As a result, only limited assumptions are made in the model, resulting in an error of less than one percent, verified by experiments. This accurate model can be used to substantially reduce energy consumption in milling processes at machine and factory levels leading to massive cost savings and reduction of environmental impact of numerous industries. The generality of the modelling method makes it applicable to other types of machine tools with minimal adjustments.

Optimization techniques for energy efficiency in machining processes—a review

“…The effect of tool wear is not investigated, and its impact on energy consumption is not considered. Imani et al [ 51 ] studied the milling operation considering machine tools as a thermodynamic system and expressed power consumption as a function of spindle speed “ n ,” feed rate, and the MRR.…”

“…On the other hand, conventional emulsions with cooling/lubricating characteristics play a vital role to reduce tool wear, and to improve product quality, and machinability [ 199 ]. In this sense, several researchers used emulsions in the machining process namely Lu and Wang who used a mixture consisting of 5% emulsifier and 95% water by volume for the turning process of AISI 1045 steel [ 51 , 77 ]. In the drilling operation of the same material, Jia et al used a plain water-based emulsion [ 72 ].…”

Development of an Empirical Model for Variable Power Consumption Machining Processes: A Case of End Facing

“…Edem and Mativenga [26] incorporated the weight of the feed drive and workpiece into the energy consumption model and improved the practical applicability of the energy model in actual machining. Imani Asrai et al [29] evaluated the energy consumption of a milling process by considering the machine tool as a thermodynamic system. He et al [27] evaluated the total energy consumption of a machine tool by dividing it into fixed energy, coolant energy, feed energy, spindle energy and cutting energy.…”

Platform for Monitoring and Comparing Machining Processes in Terms of Energy Efficiency

“…The second group includes energy consumption correlations models that analyze the relation between energy consumption and parameters of the machining process. Researchers employed tool wear [28,33,34], material properties [35] cutting force [23,36] and cutting parameters [37,38] in the process of modelling energy consumption in milling. Luan [36] develop a relatively precise power prediction model based on the infinitesimal cutting force during the face milling process.…”