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An improved micro analysis-based energy consumption and carbon emissions modeling approach for a milling center

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Abstract

The complex structure and large number of energy-consuming components in a machine tool provide a constant challenge to the researchers to characterize and model the energy consumption during a machining process. Recently, Therblig-based energy model in conjunction with value stream mapping has been used to identify and reduce the energy waste in a turning process. However, this model does not depict the information of energy consumption and carbon emissions throughout the process. Hence, it is difficult to estimate how much energy consumption and carbon emissions are caused by each activity. This paper presents an improved micro analysis of the energy and carbon emissions for each activity of a machining process on a value stream map. A case study of milling process is provided to illustrate the proposed methodology. The case study shows the improvement in energy efficiency, time efficiency, and carbon emissions. The energy and carbon emissions of each activity provide better transparency of energy flow and carbon emissions information throughout the machining process. The proposed methodology can not only be used to reduce the peak load at the factory level but also help to develop potential energy and carbon emission reduction strategies during the process planning stage.

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Abbreviations

CNC:

Computer numeric control

VSM:

Value stream map

CSM:

Current state map

FSM:

Future state map

TVSM:

Therblig-based value stream map

NC:

Numeric control

TT:

Therblig time

ATR:

Activity Therblig relationship

TP:

Therblig powers

VMC :

Vertical milling center

RPM:

Rotation per minute

CE:

Carbon emission

VAT:

Value-added Therbligs

NVAT:

Non-value-added Therbligs

VAA:

Value-added activity

NVAA:

Non-value-added activity

UNVAA:

Unnecessary non-value-added activities

NNVAA:

Necessary non-value-added activity

t i :

Duration of ith activity

s ij :

Execution state of jth Therblig in ith activity

p ij :

Power of jth Therblig in ith activity

E j :

Energy consumed by Therblig j

E i :

Energy consumed by activity i

T :

Time

CEenergy :

Carbon emissions caused by energy

CEcoolant :

Carbon emissions caused by coolant consumption

CEFenergy :

Carbon emission factor for electricity

ECprocess :

Energy consumed during the machining process

PT:

Processing time

CEFcoolant :

Carbon emissions factor for production of coolant

CEFcoolant − dis :

Carbon emissions factor for disposal of coolant

V in :

Volume of cutting fluid used initially

V ad :

Volume of additional cutting fluid used before coolant replacement

δ :

Concentration of the coolant

C/T:

Cycle time

C/O:

Change over time

η time :

Time efficiency

η A :

Energy efficiency at the activity level

η T :

Energy efficiency at Therblig level

P SR :

Unloaded spindle power

CEtotal :

Total carbon emission of the machining process

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  1. Birla Institute of Technology and Science Pilani, Vidya Vihar, Pilani, Rajasthan, 333031, India

    Nitesh Sihag & Kuldip Singh Sangwan

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  1. Nitesh Sihag
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  2. Kuldip Singh Sangwan
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Correspondence to Kuldip Singh Sangwan.

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Sihag, N., Sangwan, K.S. An improved micro analysis-based energy consumption and carbon emissions modeling approach for a milling center. Int J Adv Manuf Technol 104, 705–721 (2019). https://doi.org/10.1007/s00170-019-03807-x

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