Abstract
Energy consumption is essential in manufacturing processes. The energy associated with manufacturing must be modelled and minimised, for its efficient and effective use. Models for predicting direct energy requirements have been developed to date. This research proposes total energy requirements in machining – considering the direct and embodied energy. A new comprehensive model for obtaining cutting conditions based on minimum energy consumption in machining processes is developed. The mathematical model is informed by sensor-based energy monitoring during machining and by a methodology that evaluates the embodied energy of material consumables. The results show that the energy embodied in workpiece material and machine modules dominates the energy footprint of cutting processes. Thus, net-shape process components and low-energy footprint machine tools are recommended in order to reduce the environmental footprint of machining. The research contributes a new model to comprehensively quantify the direct and embodied energy of machining and to select machining parameters to minimise energy footprint.