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A systematic method of optimization of machining parameters considering energy consumption, machining time, and surface roughness with experimental analysis

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Abstract

For improving energy efficiency of machining process, extensive studies focused on how to establish energy consumption model and optimize cutting parameters. However, the existing methods lack a systematic method to promote the widespread use of energy efficiency methods in industry. This paper proposes a systematic method integrating energy model, experiment design, and multi-objective optimization model. Firstly, the energy model is established considering cutting energy and non-cutting energy. Then, the orthogonal experiment is designed with the three levels of four factors of spindle speed, feed speed, cutting depth, and cutting width in the X and Y cutting directions. The data of energy consumption, surface quality, and machining time are obtained to study the effects of different cutting elements and cutting directions. Meanwhile, the standby, spindle idling, feed, SEC (specific energy consumption), material cutting, and idling feed models of the CNC machine tools are established based on the experimental data. Additionally, five sets of experimental data are tested for verifying the accuracy of the established energy consumption model, which can reach 99.4%. Finally, a multi-objective optimization model for high efficiency and energy saving of processing process is established to optimize the cutting parameters considering energy consumption, processing time, and surface quality simultaneously. Combining the case of milling with constraints including machine tool performance, tool life, processing procedures, and processing requirements, the Pareto solution set is used to solve the Pareto of the target model. Through drawing a three-dimensional needle graph and two-dimensional histogram, the optimal cutting parameter combination for rough machining and semi-finish machining is provided assisting in promoting the application of the sustainable techniques in the industry.

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All the data have been presented in the manuscript.

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Acknowledgements

Guozhen Bai, Yilong Wu, and Xiang Chen are thanked for providing technical support during the experiments.

Funding

This research is funded by the National Natural Science Foundation of China Grant No. 51605294.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai, 200093, China

    Chunhua Feng, Haohao Guo, Jingyang Zhang, Yugui Huang & Shi Huang

Authors
  1. Chunhua Feng
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  2. Haohao Guo
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  3. Jingyang Zhang
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  4. Yugui Huang
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  5. Shi Huang
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Contributions

Chunhua Feng: conceptualization, methodology, software, validation, writing-original draft, funding acquisition. Haohao Guo: investigation, data curation, software. Jingyang Zhang: investigation, data curation, resources. Yugui Huang: investigation, data curation, resources. Shi Huang: methodology, software, validation, writing-original draft.

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Correspondence to Chunhua Feng.

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Feng, C., Guo, H., Zhang, J. et al. A systematic method of optimization of machining parameters considering energy consumption, machining time, and surface roughness with experimental analysis. Int J Adv Manuf Technol 119, 7383–7401 (2022). https://doi.org/10.1007/s00170-022-08772-6

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  • DOI: https://doi.org/10.1007/s00170-022-08772-6

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