Abstract
Sustainable machining as a critical part in sustainable manufacturing has been valued by manufacturing enterprises of all sizes. The traditional short-term financial considerations are substituted by longer-term sustainable strategies to ensure the competitiveness, and ultimately, the survival of the company. Energy-efficient machining system, which promotes sustainable machining, is the focus of this paper. The energy-efficient machining system requires a comprehensive understanding as well as optimisation of energy consumption. Literature in this field is carefully reviewed and summarised. Energy consumption models, which are regarded as the core of the energy-efficient machining systems, are grouped into four categories, i.e. theoretical, empirical, discrete event-based, and hybrid models. Then, energy optimisation methodologies and strategies are discussed for energy-efficient process planning and production scheduling. The applications such as tool condition monitoring can employ energy information as useful input. Research inspired by energy-efficient machining studies is briefly introduced. The main elements of an individual energy-efficient machining system are then summarised. Discussions, research suggestions, and future directions are given at the end.
Similar content being viewed by others
References
Bruntland GH (1987) Our common future. Oxford University Press, Oxford
Park CW, Kwon KS, Kim WB, Min BK, Park SJ, Sung IH, Yoon YS, Lee KS, Lee OH, Seok J (2009) Energy consumption reduction technology in manufacturing - a selective review of policies, standards, and research. Int J Precis Eng Manuf 10(5):151–173
Hanley N, McGregor PG, Swales JK, Turner K (2009) Do increases in energy efficiency improve environmental quality and sustainability? Ecol Econ 68(3):692–709
Gutowski TG (2011) Manufacturing and the science of Sustainability. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 32–39
Gutowski T, Murphy C, Allen D, Bauer D, Bras B, Piwonka T, Sheng P, Sutherland J, Thurston D, Wolff E (2005) Environmentally benign manufacturing: observations from Japan, Europe and the United States. J Clean Prod 13(1):1–17
Romvall K, Wiktorsson M, Bellgran M (2010) Competitiveness by integrating green perspective in production—a review presenting challenges for research and industry. In: Flexible Automation and Intelligent Manufacturing, FAIM, California, USA
Jovane F, Yoshikawa H, Alting L, Boër CR, Westkamper E, Williams D, Tseng M, Seliger G, Paci AM (2008) The incoming global technological and industrial revolution towards competitive sustainable manufacturing. CIRP Ann Manuf Technol 57(2):641–659
Campos JG, Marín RM, López JS, Quiroga JIA (2010) Machine model-based remote maintenance and fault analysis system for custom-made CNC machines. Int J Manuf Res 5(1):26–38
Ilgin MA, Gupta SM (2010) Environmentally conscious manufacturing and product recovery (ECMPRO): a review of the state of the art. J Environ Manag 91(3):563–591
Hauschild M, Jeswiet J, Alting L (2005) From life cycle assessment to sustainable production: status and perspectives. CIRP Ann Manuf Technol 54(2):535–555
Seuring S, Müller M (2008) From a literature review to a conceptual framework for sustainable supply chain management. J Clean Prod 16(15):1699–1710
Dornfeld D (2011) Leveraging manufacturing for a sustainable future. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 17–21
Gupta DP (2005) Energy sensitive machining parameter optimization model. Master thesis, West Virginia University, Morgantown, West Virginia
Diaz N, Helu M, Jayanathan S, Chen Y, Horvath A, Dornfeld D (2010) Environmental analysis of milling machine tool use in various manufacturing environments. In: Proceedings of the 2010 I.E. International Symposium on Sustainable Systems and Technology
Thiede S, Herrmann C (2010) Simulation-based energy flow evaluation for sustainable manufacturing systems. In: 17th CIRP International Conference on Life Cycle Engineering, Hefei, China. pp 99–104
Yuan CY, Dornfeld DA (2009) Reducing the environmental footprint and economic costs of automative manufacturing manufacturing through an alternative energy supply. In: Transactions of 37th North American Manufacturing Research Conference, Greenville, South Caroline, USA. pp 427–434
Peng T, Xu X (2011) A framework of an energy-informed machining system. In: Proceedings of the 7th International Conference on Digital Enterprise Technology, Athens, Greece. pp 160–169
Kara S, Bogdanski G, Li W (2011) Electricity metering and monitoring in manufacturing systems. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 1–10
Dahmus JB, Gutowski TG (2004) An environmental analysis of machining. In: Proceedings of International Mechanical Engineering Congress and RD&D Expo, Anaheim, California, USA. pp 643–652
Avram O, Stroud I, Xirouchakis P (2010) A multi-criteria decision method for sustainability assessment of the use phase of machine tool systems. Int J Adv Manuf Technol 53(5–8):811–828. doi:10.1007/s00170-010-2873-2
Diaz N, Choi S, Helu M, Chen Y, Jayanathan S, Yasui Y, Kong D, Pavanaskar S, Dornfeld D (2010) Machine tool design and operation strategies for green manufacturing. In: Proceedings of 4th CIRP International Conference on High Performance Cutting
Ruiz D, Ruiz CA (2009) Industrial experience in the deployment of real time online energy management systems. Comput Aided Chem Eng 27:1455–1460
Arinez J, Biller S (2010) Integration requirements for manufacturing-based energy management systems. In: Proceedings of the IEEE PES Conference on Innovative Smart Grid Technologies
Mouzon G, Yildirim MB, Twomey J (2007) Operational methods for minimization of energy consumption of manufacturing equipment. Int J Prod Res 45(18–19):4247–4271
Pechmann A, Schöler I (2011) Optimizing energy costs by intelligent production scheduling. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 293–298
Saidur R (2010) A review on electrical motors energy use and energy savings. Renew Sust Energ Rev 14(3):877–898
Abele E, Sielaff T, Schiffler A, Rothenbücher S (2011) Analyzing energy consumption of machine tool spindle units and identification of potential for improvements of efficiency. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 280–285
Kordonowy DN (2002) A power assessment of machining tools. Massachusetts Institute of Technology, Cambridge
Gutowski T, Dahmus J, Thiriez A (2006) Electrical energy requirements for manufacturing processes. In: 13th CIRP International Conference on Life Cycle Engineering, Leuven, Belgium
Li W, Zein A, Kara S, Herrmann C (2011) An investigation into fixed energy consumption of machine tools. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 268–273
Avram OI, Xirouchakis P (2011) Evaluating the use phase energy requirements of a machine tool system. J Clean Prod 19(6–7):699–711
Diaz N, Helu M, Jarvis A, Tonissen S, Dornfeld D, Schlosser R (2009) Strategies for minimum energy operation for precision machining. In: Proceedings of Machine Tool Technologies Research Foundation annual meeting, Shanghai, China
MTConnect (2008) What is MTConnect? http://mtconnect.org/index.php?option=com_content&task=view&id=15&Itemid=1.
Kuhrke B, Schrems S, Eisele C, Abele E (2010) Methodology to assess the energy consumption of cutting machine tools. In: 17th CIRP International Conference on Life Cycle Engineering, Hefei, China. pp 76–82
Anderberg S, Kara S, Beno T (2010) Impact of energy efficiency on computer numerically controlled machining. Proc Inst Mech Eng B J Eng Manuf 224(4):531–541
Munoz AA, Sheng P (1995) An analytical approach for determining the environmental impact of machining processes. J Mater Process Technol 53(3–4):736–758
Bayoumi AE, Yücesan G, Hutton DV (1994) On the closed form mechanistic modeling of milling: specific cutting energy, torque, and power. J Mater Eng Perform 3(1):151–158
Shao H, Wang HL, Zhao XM (2004) A cutting power model for tool wear monitoring in milling. Int J Mach Tools Manuf 44(14):1503–1509
Kishawy HA, Kannan S, Balazinski M (2004) An energy based analytical force model for orthogonal cutting of metal matrix composites. CIRP Ann Manuf Technol 53(1):91–94
Palanisamy P, Rajendran I, Shanmugasundaram S, Saravanan R (2006) Prediction of cutting force and temperature rise in the end-milling operation. Proc Inst Mech Eng B J Eng Manuf 220(10):1577–1587
Jerard RB, Xu M, Fussell BK (2006) Cutting power model-sensor integration for tool condition monitoring. In: Proceedings of the 34th North American Manufacturing Research Conference, Milwaukee. pp 13–15
Xu M, Jerard RB, Fussell BK (2007) Energy based cutting force model calibration for milling. Comput Aided Des Appl 4(1–6):341–351
Draganescu F, Gheorghe M, Doicin CV (2003) Models of machine tool efficiency and specific consumed energy. J Mater Process Technol 141(1):9–15. doi:10.1016/s0924-0136(02)00930-5
Radhakrishnan T, Nandan U (2005) Milling force prediction using regression and neural networks. J Intell Manuf 16(1):93–102
Kadirgama K, Abou-El-Hossein K (2005) Power prediction model for milling 618 stainless steel using response surface methodology. Am J Appl Sci 2(7):1182–1187
Kadirgama K, Abou-El-Hossein KA (2007) Torque, power and cutting force prediction model by using response surface method and factorial design. Eur J Sci Res 18(1):20–44
Aggarwal A, Singh H, Kumar P, Singh M (2008) Optimizing power consumption for CNC turned parts using response surface methodology and Taguchi’s technique-a comparative analysis. J Mater Process Technol 200(1–3):373–384
Yun-qi G, Min L, Gang W, Yi-li F (2009) Knowledge-based calculation and prediction of energy consumption in product manufacturing process. J South China Univ Technol 37(2):14–19
Neugebauer R, Wertheim R, Hochmuth C, Schmidt G, Dix M (2010) Modelling of energy and resource-efficient machining. In: 4th CIRP International Conference on High Performance Cutting.
Al-Hazza MHF, Adesta EYT, Ali FM, Agusman D, Suprianto MY (2011) Energy cost modeling for high speed hard turning. J Appl Sci 11(14):2578–2584. doi:10.3923/jas.2001
Quintana G, Ciurana J, Ribatallada J (2011) Modelling power consumption in ball-end milling operations. Mater Manuf Process 26(5):746–756
Dietmair A, Verl A (2008) Energy consumption modeling and optimization for production machines. In: Proceedings of the IEEE International Conference on Sustainable Energy Technologies. pp 574–579
Dietmair A, Verl A (2009) A generic energy consumption model for decision making and energy efficiency optimisation in manufacturing. Int J Sustain Eng 2(2):123–133
Verl A, Abele E, Heisel U, Dietmair A, Eberspächer P, Rahäuser R, Schrems S, Braun S (2011) Modular modeling of energy consumption for monitoring and control. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 341–342
Frigerio N, Matta A, Ferrero L, Rusinà F (2013) Modeling energy states in machine tools: an automata based approach. In: Proceedings of the 20th CIRP International Conference on Life Cycle Engineering, Singapore. pp 203–208
Larek R, Brinksmeier E, Meyer D, Pawletta T, Hagendorf O (2011) A discrete-event simulation approach to predict power consumption in machining processes. Production Engineering In press. pp 1–5. doi:10.1007/s11740-011-0333-y
He Y, Liu B, Zhang X, Gao H, Liu X (2012) A modeling method of task-oriented energy consumption for machining manufacturing system. J Clean Prod 23(1):167–174
Stoldt J, Schlegel A, Franz E, Langer T, Putz M (2013) Generic energy-enhancement module for consumption analysis of manufacturing processes in discrete event simulation. In: Proceedings of the 20th CIRP International Conference on Life Cycle Engineering, Singapore. pp 165–170
Schmitt R, Bittencourt JL, Bonefeld R (2011) Modelling machine tools for self-optimisation of energy consumption. In: Glocalized Solutions for Sustainability in Manufacturing—Proceedings of the 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 253–257
He Y, Liu F, Wu T, Zhong F-P, Peng B (2012) Analysis and estimation of energy consumption for numerical control machining. Proc Inst Mech Eng B J Eng Manuf 226(2):255–266. doi:10.1177/0954405411417673
Jia S, Tang R, Lv J (2013) Therblig-based energy demand modeling methodology of machining process to support intelligent manufacturing. Journal of Intelligent Manufacturing 1–19. doi:10.1007/s10845-012-0723-9
Bi ZM, Wang L (2012) Optimization of machining processes from the perspective of energy consumption: a case study. J Manuf Syst 31:420–428. doi:10.1016/j.jmsy.2012.07.002
Dietmair A, Verl A (2010) Energy consumption assessment and optimisation in the design and use phase of machine tools. In: 17th CIRP International Conference on Life Cycle Engineering, Hefei, China. pp 116–121
Peng T, Xu X (2013) A universal hybrid energy consumption model for CNC machining systems. In: Proceedings of the 20th CIRP International Conference on Life Cycle Engineering, Singapore
Balogun VA, Mativenga PT (2012) Modelling of direct energy requirements in mechanical machining processes. J Clean Prod 41:179–186
Newman ST, Nassehi A, Imani-Asrai R (2012) Energy efficient process planning for CNC machining. CIRP J Manuf Sci Technol 5(2):127–136
Schlechtendahl J, Eberspächer P, Verl A (2012) Model based consumption monitoring and control. In: 22nd International Conference on Flexible Automation and Intelligent Manufacturing, Helsinki, Finland
Schlechtendahl J, Sommer P, Eberspächer P, Verl A (2012) Automated linkage of consumption models and control information in control systems. In: Proceedings of the 19th CIRP International Conference on Life Cycle Engineering, Berkeley, US
Peng T, Xu X, Heilala J (2012) Energy-efficient machining via energy data integration. In: Emmanouilidis C, Taisch M, Kiritsis D (eds) Competitive Manufacturing for Innovative Products and Services: Proceedings of the APMS 2012 Conference, Advances in Production Management Systems, Rhodes island, Greece. IFIP Advances in Information and Communication Technology
Sheng P, Srinivasan M, Kobayashi S (1995) Multi-objective process planning in environmentally conscious manufacturing: a feature-based approach. CIRP Ann Manuf Technol 44(1):433–437
Srinivasan M, Sheng P (1999) Feature-based process planning for environmentally conscious machining—Part 1: microplanning. Robot Comput Integr Manuf 15(3):257–270
Srinivasan M, Sheng P (1999) Feature-based process planning in environmentally conscious machining—Part 2: macroplanning. Robot Comput Integr Manuf 15(3):271–281
Krishnan N, Sheng PS (2000) Environmental versus conventional planning for machined components. CIRP Ann Manuf Technol 49(1):363–366
Zhu CB, Midha PS, Trmal GJ (1993) A dynamic modelling approach to computer aided optimum selection of grinding parameters. J Mater Process Technol 38(1–2):227–245
Kaldos A, Dagiloke IF, Boyle A (1996) Computer aided cutting process parameter selection for high speed milling. J Mater Process Technol 61(1–2):219–224
He Y, Liu F, Cao H, Zhang H (2007) Process planning support system for green manufacturing and its application. Front Mech Eng China 2(1):104–109
Gupta A, Singh H, Aggarwal A (2011) Taguchi-fuzzy multi output optimization (MOO) in high speed CNC turning of AISI P-20 tool steel. Expert Syst Appl 38(6):6822–6828
Mori M, Fujishima M, Inamasu Y, Oda Y (2011) A study on energy efficiency improvement for machine tools. CIRP Ann Manuf Technol 60(1):145–148
Klocke F, Schlosser R, Lung D (2010) Energy and resource consumption of cutting processes—how process parameter variations can optimise the total process efficiency. In: 17th CIRP International Conference on Life Cycle Engineering, Hefei, China. pp 111–115
Jin K, Zhang HC, Balasubramaniam P, Nage S (2009) A multiple objective optimization model for environmental benign process planning. In: Proceedings 2009 I.E. 16th International Conference on Industrial Engineering and Engineering Management. pp 869–873
An L (2011) Optimal selection of machining parameters for multi-pass turning operations. Adv Mater Res 156–157:956–960
Rajemi MF, Mativenga PT, Aramcharoen A (2010) Sustainable machining: selection of optimum turning conditions based on minimum energy considerations. J Clean Prod 18(10–11):1059–1065
Calvanese ML, Albertelli P, Matta A, Taisch M (2013) Analysis of energy consumption in cnc machining centers and determination of optimal cutting conditions. In: Proceedings of the 20th CIRP International Conference on Life Cycle Engineering, Singapore. pp 227–232
Taha Z, Kurniati H, Aoyama H, Ghazilla RA, Gonzales J, Sakundarini N (2010) Linkage of power consumption to design feature on turning process. In: 10th WSEAS International Conference on Robotics, Control and Manufacturing Technology, Hangzhou, China. pp 74–78
Cannata A, Karnouskos S, Taisch M (2009) Energy efficiency driven process analysis and optimization in discrete manufacturing. In: Proceedings of Industrial Electronics Conference. pp 4449–4454
Klein A, Jerzak Z (2010) GINSENG for sustainable energy awareness: Flexible energy monitoring using wireless sensor nodes. In: Proceedings of the 4th ACM International Conference on Distributed Event-Based Systems. pp 109–110
Yan H, Fei L (2010) Methods for integrating energy consumption and environmental impact considerations into the production operation of machining processes. Chin J Mech Eng 23:1–8
Mani M, Lyons KW, Rachuri S, Subrahmanian E, Ameta G, Sriram RD, Feng SC (2009) Introducing sustainability early into manufacturing process planning. In: Proceedings of the 14th International Conference on Manufacturing Science and Engineering, Evanston, IL, USA. pp 319–326
Behrendt T, Zein A, Min S (2012) Development of an energy consumption monitoring procedure for machine tools. CIRP Ann Manuf Technol 61(1):43–46
Hu S, Liu F, He Y, Hu T (2012) An on-line approach for energy efficiency monitoring of machine tools. J Clean Prod 27(1):133–140
Warndorf P, Fox A, Sobel W (2007) MTConnect Technology White Paper. Association for Manufacturing Technology. www.mtconnect.org
Mani MLM, Leong S, Lyons K, Ranta A, Lkkala K, Bengtsson N (2010) Impact of energy measurements in machining operations. In: Proceedings of the ASME 2010 International Design Engineering Technical Conference & Computers and Information in Engineering Conference, Montreal, Quebec, Canada
Lee BE, Michaloski J, Proctor F, Venkatesh S, Bengtsson N (2010) MT-connect-based kaizen for machine tool processes. In: Proceedings of ASME 2010 International Design Engineering Technical Conference & Computers and Information in Engineering Conference, Montreal, Quebec, Canada
Vijayaraghavan A, Dornfeld D (2010) Automated energy monitoring of machine tools. CIRP Ann Manuf Technol 59(1):21–24
Byrne G, Dornfeld D, Inasaki I, Ketteler G, König W, Teti R (1995) Tool Condition Monitoring (TCM)—the status of research and industrial application. CIRP Ann Manuf Technol 44(2):541–567
Abellan-Nebot JV, Romero Subirón F (2010) A review of machining monitoring systems based on artificial intelligence process models. Int J Adv Manuf Technol 47(1–4):237–257
Teti R, Jemielniak K, O’Donnell G, Dornfeld D (2010) Advanced monitoring of machining operations. CIRP Ann Manuf Technol 59:717–739
Rehorn AG, Jiang J, Orban PE (2005) State-of-the-art methods and results in tool condition monitoring: a review. Int J Adv Manuf Technol 26(7–8):693–710
Liang SY, Hecker RL, Landers RG (2004) Machining process monitoring and control: the state-of-the-art. J Manuf Sci Eng Trans ASME 126(2):297–310
Lee BY, Tarng YS (1999) Application of the discrete wavelet transform to the monitoring of tool failure in end milling using the spindle motor current. Int J Adv Manuf Technol 15(4):238–243
Kim HY, Ahn JH, Kim SH, Takata S (2002) Real-time drill wear estimation based on spindle motor power. J Mater Process Technol 124(3):267–273
Amer W, Ahsan Q, Grosvenor RI, Prickett PW (2005) Machine tool condition monitoring system using Tooth Rotation Energy Estimation (TREE) technique. In: IEEE Symposium on Emerging Technologies and Factory Automation. pp 529–536
Al-Sulaiman FA, Baseer MA, Sheikh AK (2005) Use of electrical power for online monitoring of tool condition. J Mater Process Technol 166(3):364–371
Li X, Du R, Denkena B, Imiela J (2005) Tool breakage monitoring using motor current signals for machine tools with linear motors. IEEE Trans Ind Electron 52(5):1403–1408
Jeswiet J, Kara S (2008) Carbon emissions and CES™ in manufacturing. CIRP Ann Manuf Technol 57(1):17–20
Byrne G, Scholta E (1993) Environmentally clean machining processes—a strategic approach. CIRP Ann Manuf Technol 42(1):471–474
Popke H, Emmer T, Steffenhagen J (1999) Environmentally clean metal cutting processes—Machining on the way to dry cutting. Proc Inst Mech Eng B J Eng Manuf 213(3):329–332
Weinert K, Inasaki I, Sutherland JW, Wakabayashi T (2004) Dry machining and minimum quantity lubrication. CIRP Ann Manuf Technol 53(2):511–537
Peng T, Xu X (2012) The state of the art in energy consumption model—the key to sustainable machining. Appl Mech Mater 232:592–599. doi:10.4028/www.scientific.net/AMM.232.592
Brecher C, Triebs J, Jasper D (2013) Energy efficient solutions for hydraulic units of machine tools. In: Proceedings of the 20th CIRP International Conference on Life Cycle Engineering, Singapore. pp 191–196
Sekler P, Verl A (2009) Real-time computation of the system behaviour of lightweight machines: A possible way for vibration reduction for production machines. In: First International Conference on Advances in System Simulation. pp 144–147
Dietmair A, Zulaika J, Sulitka M, Bustillo A, Verl A (2010) Lifecycle impact reduction and energy savings through light weight eco-design of machine tools. In: 17th CIRP International Conference on Life Cycle Engineering, Hefei, China. pp 105–110
Diaz N, Redelsheimer E, Dornfeld D (2011) Energy consumption characterization and reduction strategies for milling machine tool use. In: 18th CIRP International Conference on Life Cycle Engineering, Braunschweig, Germany. pp 263–267
Ad T, Tonchia S (1998) Manufacturing flexibility: a literature review. Int J Prod Res 36(6):1587–1617
Ohno T (1998) Toyota production system: beyond large-scale production. Productivity Press, Cmbridge
Shen W, Hao Q, Yoon HJ, Norrie DH (2006) Applications of agent-based systems in intelligent manufacturing: an updated review. Adv Eng Inform 20(4):415–431
Xu X (2012) From cloud computing to cloud manufacturing. Robot Comput Integr Manuf 28(1):75–86
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Peng, T., Xu, X. Energy-efficient machining systems: a critical review. Int J Adv Manuf Technol 72, 1389–1406 (2014). https://doi.org/10.1007/s00170-014-5756-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-5756-0