An empirical model for predicting energy consumption of manufacturing processes: a case of turning process

Optimizing the energy efficiency of processes has become a priority in the manufacturing sector; driven by soaring energy costs and the environmental impact caused by high energy consumption levels. The energy consumed by a machine tool performing a turning process consists of not only the energy required by the tool tip for material removal but also the energy used for auxiliary functions. Traditionally, the energy required for the cutting process is estimated based on cutting force prediction equations. However, this estimation is limited to the energy consumption of the tool tip. Thus, the aim of this paper is to develop a reliable method to predict the total energy consumption of a selected machine tool performing a turning operation. In order to compare the energy consumption under different cutting conditions, the specific energy consumption is defined as a functional unit: the energy consumed to remove 1 cm(3) of material. An empirical model is obtained based on power measurements under various cutting conditions, and it is able to provide a reliable prediction of energy consumption for given process parameters. Additional investigations are conducted in order to understand and explain each coefficient in the energy consumption model.