Optimization techniques for energy efficiency in machining processes—a review

Abstract

Metal working process is one of the main activities in mechanical manufacturing industry; it is considered as a major consumer of energy and natural resources. In material removal process, the selection of cutting parameters and cooling or cutting liquid is necessary to save energy and achieve energy efficiency as well as sustainability. During the last two decades, the number of publications in this field has rapidly increased and has shown the importance of this research area. This review paper identifies and reviews in detail a total of 166 scientific studies which exhibit original contributions to the field and address multiple energy efficiency challenges. The recently developed models of energy consumption and different materials used in the machining process are presented. Therefore, this study describes various techniques for modeling and optimizing machining operations such as turning, milling, and drilling. Modeling techniques, experimental methods, multi-objective and single-objective optimization methods, and hybrid techniques optimization are presented in a detailed manner compared to previous review papers where only energy models are discussed. It can help practitioners and researchers to select the most appropriate approach for the desired experience and to highlight the progress of these methods in terms of machining energy efficiency. Additionally, this paper provides a review of different cutting fluids adopted in machining processes. This paper assists researchers and manufacturers in making advantageous technical decisions that have substantial economics in terms of energy saving.

Impacto ambiental de los procesos industriales de mecanizado por arranque de viruta con tornos paralelos mediante métodos innovadores: revisión del estado del arte

“…Técnicamente, hasta dos tercios del total de la energía consumida en las operaciones de mecanizado no se aprovechan ya que se convierten en calor y el resto lo consumen los ejes de alimentación, accesorios, motores inactivos, controladores y otros elementos electrónicos fijos (Zohra et al, (2023). Las estadísticas de la U.S. Energy Information Administration (2020).…”

Integrated Production-Maintenance Strategy considering energy consumption and recycling constraints in dry machining

“…Several studies, [24], [25], reviewed energy-efficient machining systems and discussed the energy consumption associated with machining processes. It is noteworthy that the cutting process itself accounts for only a small portion of energy consumption, while the majority is attributed to losses, idle running, and secondary systems.…”

Integrated Energy Use Optimisation and Cutting Parameter Prediction Model - Aiding Process Planning of Ti6Al4V Machining on the CNC Lathe

“…Machining is one of the primary activities in the mechanical manufacturing process, [1], of cylindrical Ti6Al4V component parts used in the aerospace industry. The cutting of metallic components by machine tools is considered a significant electrical energy consuming activity of the manufacturing process [2]. Determining the optimal machining parameter settings point which improves the energy use efficiency and escalate the process yield of grade 5 titanium alloy processing, therefore, offers significant opportunities of financial benefits for the machining industry operations.…”

“…3.1 The IEUOCPPTM DevelopmentOnce data was tabulated, mathematical models, expressing the response parameters as function of the input variables (cutting speed (vc) and feed rate (fn)), were developed using regression analysis modelling on Minitab 18 software. Further development involved expressing the performance parameters -Material Removal Rate (MRR), Segmentation Teeth Pitch (STP), Tool Wear (TW), Main cutting force (Fz) and average Surface roughness (Ra) -as functions of specific cutting energy, SE.Equations 1 to 5 were determined as related to the individual response parameters where the variables are respectively represented thus, y, is the specific cutting energy J/m 3 , vc, cutting speed (m/min) and fn, feed rate (mm/rev): + 14.791382406(𝑣𝑐)(𝑓𝑛)-19180.8816214(𝑓𝑛) 31789.178373(𝑓𝑛)2(2) …”