Abstract
CNC milling machine is a production machine which widely used to manufacture many kinds of products. In the process of milling machining, the time needed to produce a component must be as minimum as possible to minimize the costs and its impacts on the environment. One of energy consumptions used in CNC milling machines is to supply electric motors for each axis of motions. Cutting energy consumption can be minimized by optimizing the cutting parameters, such as the cutting toolpath. Modelling and comparing the total energy consumption of the cutting process from different cutting toolpaths and strategies are important in selecting the right toolpath that has the smallest energy consumption. To achieve this goal, this study models the energy consumption during the cutting process. The model is then used to evaluate and compare different cutting toolpaths from different cutting strategies. Three prismatic and one sculptured part were used to examine the model of cutting energy consumption. A Graphical User Interface is also developed to simplify the comparison and evaluation process. Through this process it will be possible to predict energy consumption in the cutting toolpath and hence enable the selection of the right toolpath to reduce energy consumption in machining.
Highlights
The industrial world today has an important evaluation to reduce energy consumption
The aim of this research is to evaluate and compare the energy consumption required for the spindle motor, x-axis, y-axis, and z-axis feed motor on a 3-axis milling machine by using the correlation between the NC codes generated from the different types of cutting toolpath, since a part may be manufactured by various methods with each method having different machining time and energy per component
Results of total energy consumption on each workpiece can be seen in Table 3 and Fig 4
Summary
The industrial world today has an important evaluation to reduce energy consumption. According to Fang et al [1] industrial sector today covers about one-half of the world’s energy consumption, and has almost doubled over the last 60 years. Manufacturing industry is one of the sectors responsible for this, due to the use of machinery equipment that consumes energy in the manufacturing process of a component. In the process of converting raw materials into finished components or parts, manufacturing industries are one of the major consumers for electricity usage and contribute to a large amount of carbon emissions, since electrical energy used today is generated by burning fossil fuels as their source of energy. Li et al [3] stated that more than 99% of the environmental impact was caused by the use of electrical energy consumed by machinery equipment in the process of discrete part manufacturing such as milling or turning machine
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