Computational energy estimation tools for machining operations during preliminary design

The aim of this paper is to develop computational machining energy estimation tools during the early design stage of product development. In the preliminary or embodiment design, a product's shape and materials are determined. At this stage, it is crucial for a designer to be able to compare alternative designs and materials based on many different criteria, such as cost, functionality, energy, etc. Automated tools for estimating energy consumption that could later be used to integrate with CAD/CAM systems are in demand. This study presents computational tools for estimating the energy consumption of machining operations during the early design phase. The computational tools utilize a preliminary computer representation of a product (CAD model), its material and candidate machining operations to automatically analyse and estimate a range of energy consumption during machining operations. Detailed steps for computing turning and milling energy consumption are presented. Case studies of both parts and assemblies were conducted to test the validity of the tools and to evaluate the performance of the tools. Environmental impacts such as carbon weight will also be estimated. The computation tools will assist users with little knowledge about energy computations to estimate energy consumption during the design stage. Such energy estimation can be used to redesign parts and assemblies, leading to the development of products with reduced machining energy. The computation tools are part of a larger research on estimating energy consumption throughout a product's life cycle.