Abstract
Mechanical manufacturing industry consumes substantial energy with low energy efficiency. Increasing pressures from energy price and environmental directive force mechanical manufacturing industries to implement energy efficient technologies for reducing energy consumption and improving energy efficiency of their machining processes. In a practical machining process, cutting parameters are vital variables set by manufacturers in accordance with machining requirements of workpiece and machining condition. Proper selection of cutting parameters with energy consideration can effectively reduce energy consumption and improve energy efficiency of the machining process. Over the past 10 years, many researchers have been engaged in energy efficient cutting parameter optimization, and a large amount of literature have been published. This paper conducts a comprehensive literature review of current studies on energy efficient cutting parameter optimization to fully understand the recent advances in this research area. The energy consumption characteristics of machining process are analyzed by decomposing total energy consumption into electrical energy consumption of machine tool and embodied energy of cutting tool and cutting fluid. Current studies on energy efficient cutting parameter optimization by using experimental design method and energy models are reviewed in a comprehensive manner. Combined with the current status, future research directions of energy efficient cutting parameter optimization are presented.
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Abbreviations
- a c :
-
Clearance angle of the tool tip
- a e :
-
Cutting width
- a 1 :
-
Lead angle of the tool tip
- a p :
-
Cutting depth
- a p,max :
-
Maximum cutting depth
- a p,min :
-
Minimum cutting depth
- b spindle :
-
Unload power coefficient of spindle system
- B(n s):
-
Viscous damping coefficient of main transmission system equivalently transformed to motor shaft
- B SA :
-
Coefficient of the spindle acceleration energy
- B SRD :
-
Coefficient of the spindle deceleration energy
- C F :
-
Coefficient of cutting force
- C SA :
-
Coefficient of the spindle acceleration energy
- C SRD :
-
Coefficient of the spindle deceleration energy
- C T :
-
Coefficient of tool life
- D avg :
-
Average diameter of workpiece
- D milling :
-
Diameter of milling tool
- E ac :
-
Spindle acceleration energy
- E air :
-
Air cutting energy
- E iair :
-
Air cutting energy of the ith pass
- E iapproaching :
-
Energy consumption for tool approaching of the ith pass
- E cutting :
-
Cutting energy
- E icutting :
-
Cutting energy of the ith pass
- E dc :
-
Spindle deceleration energy
- E electrical :
-
Electrical energy of the machining process
- E electrical-dry :
-
Electrical energy of the machining process under dry condition
- E electrical-wet :
-
Electrical energy of the machining process under wet condition
- E embodied :
-
Electrical energy of machine tool and the embodied energy of consumable material
- E fluid-embodied :
-
Embodied energy consumption of cutting fluid
- E fluid-material :
-
Energy used to fabricate the material of cutting fluid
- E footprint :
-
Energy footprint of the machining process
- E functional-modules :
-
Energy consumption by main machine tool functional modules
- E idle-auxiliary :
-
Idle energy of auxiliary system
- E insert :
-
Energy to fabricate the cutting insert material
- E leaving :
-
Energy consumption for tool leaving
- E loss-motor :
-
Additional load loss energy of main motor
- E loss-moving :
-
Inertia energy loss of moving components
- E m :
-
Changed energy of electromagnetic field
- E material :
-
Material removal energy
- E rotation-changing :
-
Energy consumption for spindle rotation changing (non-cutting)
- E standby :
-
Standby energy
- E istandby :
-
Standby energy of the ith pass
- E standby-preparation :
-
Standby energy used to bring the workpiece and cutting tool to the about-to cut position and to set up the numerical control program before machining
- E startup :
-
Startup energy
- E tool-changing :
-
Standby energy used for changing the worn cutting tool
- E tool-embodied :
-
Embodied energy consumption of cutting tool
- f :
-
Feed rate
- f max :
-
Maximum feed rate
- f min :
-
Minimum feed rate
- f z :
-
Feed rate per tooth
- F cutting :
-
Cutting force
- h :
-
Deformed chip thickness
- J m(n s):
-
Rotational inertia of main transmission system equivalently transformed to motor shaft
- k m :
-
Constant for material removal power
- k spindle :
-
Unload power coefficient of spindle system
- K :
-
Cutting pressure
- l :
-
Cutting length of workpiece
- m :
-
Number of machining passes
- M om(n s):
-
Load torque of electric motor in the main transmission system
- n :
-
Spindle speed
- n teeth :
-
Average number of engaged tool teeth
- n pqEj :
-
Final spindle speed for the jth speed change in spindle rotation
- n pqSj :
-
Initial spindle speed for the jth speed change in spindle rotation
- n(t):
-
Spindle speed varying with time
- N :
-
Number of cutting edges of each insert
- P air :
-
Air cutting power
- P auxiliary :
-
Power of auxiliary system
- P pqcj :
-
Power consumption of spindle system during the jth speed change of the spindle rotation in noncutting operations from feature Fp to feature Fq
- P cutting :
-
Cutting power
- P feed-fast :
-
Power for fast feeding
- P idle-auxiliary :
-
Idle power of auxiliary system
- P loss :
-
Additional load loss power of spindle system and feed systems
- P loss-spindle :
-
Additional load loss power of spindle system
- P m :
-
Nominal motor power of spindle
- P material :
-
Material removal power
- P rated-compressed :
-
Rated power of compressed air motor
- P removal :
-
Material removal power
- P spraying-cooling :
-
Power for spraying cooling fluid
- P standby :
-
Standby power
- P startup :
-
Startup power
- P unload :
-
Unload power of spindle and feed systems
- P unload-feed :
-
Unload power of feed system
- P unload-spindle :
-
Unload power of spindle system
- R a :
-
Surface roughness
- Ra max :
-
Permitted maximum surface roughness
- t ac :
-
Time duration of spindle acceleration
- t air :
-
Air cutting time
- t cutting :
-
Cutting time
- t pqcj :
-
Time duration during the jth speed change of the spindle rotation in noncutting operations from feature Fp to feature Fq
- t end :
-
Spindle acceleration ending at this time point
- t feed-fast :
-
Time for fast feeding
- t insert-changing :
-
Time for changing an insert
- t spraying-cooling :
-
Time for spraying cooling fluid
- t st :
-
Spindle acceleration starting at this time point
- t standby-preparation :
-
Standby time used to bring the workpiece and cutting tool to the about-to cut position and to set up the numerical control program before machining
- t startup :
-
Startup time
- t tool-changing :
-
Tool changing time
- T fluid :
-
Replacement cycle of cutting fluid
- T e :
-
Economic tool life
- T SA :
-
Coefficient of the spindle acceleration energy
- T tool :
-
Tool life
- U fluid :
-
Unit embodied energy of cutting fluid
- U tool :
-
Unit embodied energy of cutting tool
- V additional :
-
Additional volume of cutting fluid
- v c :
-
Cutting velocity
- v c,max :
-
Maximum cutting velocity
- v c,min :
-
Minimum cutting velocity
- V initial :
-
Initial volume of cutting fluid
- V insert :
-
Volume of one insert
- X F :
-
Coefficient of cutting force
- y F :
-
Coefficient of cutting force
- z :
-
Number of cutting inserts
- z F :
-
Coefficient of cutting force
- α A :
-
Coefficient of the spindle system
- α F :
-
Coefficient of cutting force
- α feed :
-
Unload power coefficient of feed system
- α spindle :
-
Unload power coefficient of spindle system
- α T :
-
Coefficient of tool life
- β f :
-
Coefficient of cutting force
- β feed :
-
Unload power coefficient of feed system
- β spindle :
-
Unload power coefficient of spindle system
- β T :
-
Coefficient of tool life
- γ compressed :
-
Load factor of compressed air motor
- γ feed :
-
Unload power coefficient of feed system
- γ spindle :
-
Unload power coefficient of spindle system
- γ t :
-
Coefficient of tool life
- δ :
-
Concentration of cutting fluid
- ξ loss :
-
Additional load loss coefficient
- η m :
-
Overall efficiency of spindle motor
- λ :
-
Coefficient of cutting force
- λ loss :
-
Additional load loss coefficient
- μ F :
-
Coefficient of cutting force
- μ feed :
-
Unload power coefficient of feed system
- ρ :
-
Density of the cutting fluid
- ψ f :
-
Coefficient of cutting force
- ABC:
-
Artificial bee colony
- ANN:
-
Artificial neural network
- ANOVA:
-
Analysis of variance
- BSA:
-
Backtracking search algorithm
- DFA:
-
Desirability function analysis
- EMMBMS:
-
Energy modeling method based on machining state
- EMMBMTC:
-
Energy modeling method based on machine tool component
- GA:
-
Genetic algorithm
- GRA:
-
Gray relational analysis
- GRG:
-
Gray relational grade
- HSS:
-
High-speed steel
- MOBSA:
-
Multiobjective backtracking search algorithm
- MOEA/D:
-
Multiobjective evolutionary algorithm based on decomposition
- MOHS:
-
Multiobjective harmony search
- MOPSO:
-
Multiobjective particle swarm optimization
- MQL:
-
Minimum quantity lubrication
- MRR:
-
Material removal rate
- MRV:
-
Material removal volume
- NC:
-
Numerical control
- NSGA-II:
-
Nondominated sorting genetic algorithm II
- RSM:
-
Response surface methodology
- PCA:
-
Principal component analysis
- PSO:
-
Particle swarm optimization
- SEC:
-
Specific cutting energy, the amount of energy required to cut a unit volume of a workpiece
- SQP:
-
Sequential quadratic programming
- S/N:
-
Signal-to-noise ratio
- TOPSIS:
-
Technique for order of preference by similarity to ideal solution
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Acknowledgements
This work was supported in part by the National Natural Science Foundation of China (Grant No. 51905448), the Fundamental Research Funds for the Central Universities of China (Grant No. SWU119060), the Natural Science Foundation of Chongqing, China (Grant No. cstc2018jcyjAX0579), and the Technological Innovation and Application Development of Chongqing, China (Grant No. cstc2019jscx-mbdx0118).
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Chen, X., Li, C., Tang, Y. et al. Energy efficient cutting parameter optimization. Front. Mech. Eng. 16, 221–248 (2021). https://doi.org/10.1007/s11465-020-0627-x
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DOI: https://doi.org/10.1007/s11465-020-0627-x