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Development of an empirical model to quantify carbon emissions for machining of cylindrical parts

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Abstract

As a result of growing environmental issues and stringent carbon emission (CEM) regulations imposed throughout the globe, low CEM has become one of the essential requirements of manufacturing industries. Low-carbon manufacturing, which aims to reduce carbon intensity and improve process efficiency, has evolved as emerging issue that has encouraged a lot of research into quantifying the CEM of different manufacturing processes. To comply with increasingly stringent CEM regulations and achieve low carbon manufacturing, manufacturing industries require accurate CEM data for their products. In this work, an empirical model is developed to quantify carbon emissions for machining of cylindrical parts. The CEM associated with a cylindrical part machining is decomposed into CEM from electrical energy consumption, material consumption, cutting tool wear, and coolant consumption and from the disposal of machining waste materials. Electrical energy consumption of a machine tool is further decomposed into different energy modules: startup, standby, spindle acceleration, idle, rapid positioning, air-cutting, and cutting for accurate quantification of CEM. Energy consumption models are developed for each module, and are integrated to quantify the total energy consumption of the machine tool. Finally, the developed model is applied on a cylindrical part with three different process plans to validate the developed model for practical implementation in industry. The proposed model can be utilized in the manufacturing industry to quantify carbon emissions based on different process parameters before machining a cylindrical part to achieve low carbon manufacturing process planning and scheduling.

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Data availability

The corresponding author will share the datasets used or analyzed during the current study upon reasonable request. The article includes the most of the datasets.

Code availability

Not applicable.

Abbreviations

MRR:

Material removal rate

VPC:

Variable-power consumption

CPC:

Constant-power consumption

CEM:

Carbon emission

CO2 :

Carbon dioxide

\(CE{M}_{elec}\) :

CEM due to electrical energy consumption in kgCO2

\(CE{M}_{cool}\) :

CEM due to the coolant consumption in kgCO2

\(CE{M}_{oil}\) :

CEM due to the manufacture of pure mineral oil in kgCO2

\(CE{M}_{wc}\) :

CEM due to the disposal of cutting fluid waste in kgCO2

\(CE{M}_{tool}\) :

CEM due to the tool wear in kgCO2

\(CE{M}_{m}\) :

CEM due to the material consumption in kgCO2

\(CE{M}_{chip}\) :

CEM due to the post-processing of chips in kgCO2

\(CE{F}_{elec}\) :

CEM factor for electrical energy consumption

\({CEF}_{{oil}}\) :

CEM factor for the manufacturing of coolant

\({CEF}_{wc}\) :

CEM factor for the disposal of the used coolant

\({CEF}_{{tool}}\) :

CEM factor for the cutting tool wear

\({CEF}_{m}\) :

CEM factor for the material consumption

\({CEF}_{{chip}}\) :

CEM factor for the chips post-processing

\({V}_{{in}}\) :

Initial volume of the coolant in liter

\({V}_{ad}\) :

Additional volume of coolant in liter

\({w}_{{tool}}\) :

Weight of the cutting tool/inserts in gm

\({T}_{{life}}\) :

Tool life in seconds

\(\delta\) :

Coolant concentration in %

\({Q}_{m}\) :

Mass of material in kg

\(\rho\) :

Density of the material in g/cm3

\({v}_{c}\) :

Cutting velocity in m/min

\({v}_{\mathrm{max}}\) :

Maximum cutting velocity in m/min

\({f}_{r}\) :

Feed speed in mm/revolution

\({d}_{c}\) :

Depth of cut in mm

\(r\) :

Tool nose radius in mm

\(D\) :

Part diameter in mm

\(n\) :

Spindle angular velocity in rev/min

\({E}_{{total}}\) :

Total energy consumption in J

\({E}_{{startup}}\) :

Startup energy consumption in J

\({E}_{standby}\) :

Standby energy consumption in J

\({E}_{acc}\) :

Spindle acceleration energy consumption in J

\({E}_{{rapid}}\) :

Rapid positioning energy consumption in J

\({E}_{{idle}}\) :

Idle energy consumption in J

\({E}_{tc}\) :

Tool change energy consumption in J

\({E}_{air}\) :

Air cut energy consumption in J

\({E}_{{cool}}\) :

Coolant pump energy consumption in J

\({E}_{cut}\) :

Cutting energy consumption in J

\({E}_{cut\_CPC}\) :

CPC machining process energy consumption in J

\({E}_{cut\_VPC}\) :

VPC machining process energy consumption in J

\({P}_{{total}}\) :

Total power consumption in W

\({P}_{{startup}}\) :

Startup power consumption in W

\({P}_{standby}\) :

Standby power consumption in W

\({P}_{acc}\left(t\right)\) :

Spindle acceleration power consumption at an instant \(t\) in W

\({P}_{{rapid}}\left(t\right)\) :

Rapid positioning power consumption at an instant \(t\) in W

\({P}_{{idle}}\) :

Idle power consumption in W

\({P}_{tc}\) :

Tool change power consumption in W

\({P}_{air}\) :

Air cut power consumption in W

\({P}_{{cool}}\) :

Coolant pump power consumption in W

\({P}_{cut}\) :

Cutting power consumption in W

\({P}_{m}\) :

Material removal power consumption in W

\({P}_{m\_CPC}\) :

\({P}_{m}\) For the CPC machining process in W

\({P}_{m\_VPC}\) :

\({P}_{m}\) For the VPC machining process in W

\({P}_{cut\_CPC}\) :

\({P}_{cut}\) In the CPC machining process in W

\({P}_{cut\_VPC}\left(t\right)\) :

\({P}_{cut}\) At an instant \(t\) in the VPC machining process in W

\({P}_{f}\) :

Feed axes power consumption in W

\({P}_{fx}\) :

\(x\)-Axis feed power consumption in W

\({P}_{fz}\) :

\(z\)-Axis feed power consumption in W

\({T}_{cut}\) :

Total cutting time in second

\({t}_{stp}\) :

Startup time in second

\({t}_{std}\) :

Standby time in second

\({t}_{acc}\) :

Spindle acceleration time in second

\({t}_{{idle}}\) :

Idle time in second

\({t}_{tc}\) :

Tool change time in second

\({t}_{rpd}\) :

Rapid positioning time in second

\({t}_{air}\) :

Air cut time in second

\({t}_{{cool}}\) :

Coolant flow time in second

\({t}_{cut}\) :

Cutting time in second

\({t}_{CPC}\) :

CPC machining process time in second

\({t}_{VPC}\) :

VPC machining process time in second

\(K\), \(n\), \(p\) and \(q\) :

Tool life constants

\({x}_{i}\), \(i=\mathrm{1,2,3}\) :

Fitting coefficient of spindle acceleration energy consumption model

\({y}_{i}\), \(i=\mathrm{1,2,3}\) :

Fitting coefficient of idle power consumption model

\({C}_{CP},{\alpha }_{c}\), \({\beta }_{c}\), \({\lambda }_{c}\), \({\delta }_{c}\) :

Fitting coefficients of \({P}_{m\_CPC}\) model

\({C}_{VP},{\alpha }_{v}\), \({\beta }_{v}\), \({\lambda }_{v}\),\({\delta }_{v}\) :

Fitting coefficients of \({P}_{m\_VPC}\) model

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Authors and Affiliations

  1. Mechanical Engineering Department, Birla Institute of Technology and Science, Pilani, Rajasthan, 333031, India

    Shailendra Pawanr, Girish Kant Garg & Srikanta Routroy

Authors
  1. Shailendra Pawanr
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  2. Girish Kant Garg
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  3. Srikanta Routroy
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Contributions

Shailendra Pawanr: conceptualization, visualization, investigation, methodology, conducting experiments, writing original draft preparation. Girish Kant Garg: investigation; writing—reviewing and editing; supervision. Srikanta Routroy: editing and supervision.

Corresponding author

Correspondence to Girish Kant Garg.

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All the authors are looking forward that the final revised version of the paper has been published in Environmental Science and Pollution Research without any change.

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The authors declare no competing interests.

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Responsible Editor: Philippe Garrigues

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Pawanr, S., Garg, G.K. & Routroy, S. Development of an empirical model to quantify carbon emissions for machining of cylindrical parts. Environ Sci Pollut Res 30, 21565–21587 (2023). https://doi.org/10.1007/s11356-022-23349-2

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  • DOI: https://doi.org/10.1007/s11356-022-23349-2

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