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A quantitative approach to analyze carbon emissions of CNC-based machining systems

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Abstract

With the growing concerns on global warming, much research attention has been focused on industrial activities which largely consume energy and emit carbon to the atmosphere. Low-carbon manufacturing, aiming to reduce carbon intensity and enhance resource utilization, is then emerging as a timely topic and spurs much research into a low carbon scenario. This paper proposes an analytical method of quantifying carbon emissions of a computer numerical control (CNC)-based machining system. In particular, the paper discusses the breakdown of the processes that contribute to the overall carbon emissions of a CNC-based machining system, such as electricity, cutting fluid, wear and tear of cutting tools, material consumption and disposal of chips, etc. The way of quantifying the amount of carbon emissions from individual processes are then analyzed. Finally, the proposed methodology is applied into two different machining cases, in which the impact of different machining parameters and different machining methods on carbon emissions in the CNC machining process are analyzed, respectively.

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Abbreviations

\({ CE }_{ ms }\) :

The carbon emissions of a CNC-based machining system \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions caused by the generation of electricity necessary for machining operations \((\mathrm{kg\,CO}_{2})\)

\({ CE }_{ coolant }\) :

The carbon emissions caused by the production of cutting fluid \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions caused by the production of cutting tools \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions caused by the production of raw materials \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions generated from chip removal \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions generated through the production of pure mineral oil \((\mathrm{kg\,CO}_{2})\)

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

The carbon emissions generated by the disposal of cutting fluid waste\((\mathrm{kg\,CO}_{2})\)

\( CEF _{ elec }\) :

The electricity carbon emission factor \((\mathrm{kg\,CO}_{2}\mathrm{/kwh})\)

\( CEF _{ wc }\) :

The carbon emission factors for the disposal of cutting fluid \((\mathrm{kg\,CO}_{2}/\mathrm{L})\)

\( CEF _{m}\) :

The material carbon emission factor \((\mathrm{kg\,CO}_{2}/\mathrm{kg})\)

\( CEF _{ ce }\) :

The carbon emission factor of standard coal \((\mathrm{kg\,CO}_{2}/\mathrm{kg\,ce})\)

\( CEF _{ oil }\) :

The carbon emission factors for the production of cutting fluid \((\mathrm{kg\,CO}_{2}/\mathrm{L})\)

\( CEF _{ tool }\) :

The carbon emission factor of cutting tools \((\mathrm{kg\,CO}_{2}/\mathrm{kg})\)

\( CEF _{ chip }\) :

The carbon emission factor of chips \((\mathrm{kg\,CO}_{2}/\mathrm{kg})\)

\(d_{w}\) :

The diameter of the work piece (mm)

\(L_{w}\) :

The length of the work piece (mm)

\(M_{ chip }\) :

The mass of removed material (kg)

\(Q\) :

The material removal rate \((\mathrm{mm}^{3}/\mathrm{s})\)

\(\rho \) :

The material density \((\mathrm{g/cm}^{3})\)

\(v_{c}\) :

Cutting speed (m/s)

\(f\) :

Feed rate (mm/r)

\(a_{p}\) :

Cutting depth (mm)

\(\Delta \) :

Machining allowance (mm)

\(T_{ coolant }\) :

Cutting fluid replacement cycle time (month)

\(T\) :

Machining period (s)

\(t_{c}\) :

Cutting time (s)

\(t_{ idle }\) :

Idle time (s)

\(P_{u}\) :

Idle power (W)

\(P_{c}\) :

Cutting power (W)

\(P_{a}\) :

Additional load loss power (W)

\(P_{i}\) :

Input power (W)

\({ CC }\) :

The initial volume of cutting fluid (L)

\({ AC }\) :

Additional volume of cutting fluid (L)

\(\delta \) :

The predetermined cutting fluid concentration

\(W_{ tool }\) :

The mass of the tool (g)

\(T_{0}\) :

Tool durability (min)

\(T_{ tool }\) :

The life cycle of the tool (min)

\({ EC }_{ machine }\) :

The energy consumption of the CNC machine (kwh)

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

The embodied energy of mineral oil (GJ/L)

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

The carbon intensity of mineral oil (kg C/GJ)

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

The embodied energy of the material (MJ/kg)

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

The carbon intensity of the material (kg C/MJ)

\({ EE }_{ ce }\) :

The standard coal equivalent of the material’s embodied energy

\({ EC }_{ ce }\) :

The amount of standard coal consumed in the recycling process of a unit mass of scrap

\(C_{T}\) :

A fixed value related to cutting conditions

\(x,y,z\) :

The coefficient of tool durability

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Acknowledgments

This work is supported in part by the National Natural Science Foundation of China (51035001, 51105395), the National Key Technology R&D Program of China (2012BAF02B03), and the Fundamental Research Funds for the Central Universities of China (CDJZR12110076).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, People’s Republic of China

    Congbo Li, Longguo Cui & Pengyu Li

  2. Department of Electrical and Computer Engineering, Rowan University, Glassboro, NJ, USA

    Ying Tang

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  1. Congbo Li
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Correspondence to Congbo Li.

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Li, C., Tang, Y., Cui, L. et al. A quantitative approach to analyze carbon emissions of CNC-based machining systems. J Intell Manuf 26, 911–922 (2015). https://doi.org/10.1007/s10845-013-0812-4

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