Modelling and Verification of Energy Consumption in CNC Milling

Electrical energy consumption forms 99% of the environmental impact of machining operations. Whilst replacing existing machineries for more energy efficient ones does not deem possible in short term, process planning for machining with energy consumption in mind is a more accessible solution. The effect of cutting parameters on power consumption in CNC milling of 6082 T6 aluminum alloy was investigated in this paper. Mathematical models were developed to estimate the energy and power consumption in CNC milling machines. The analysis indicated that the two less studied parameters of axial and radial depth of cut have significant impact on the total energy consumption of machining processes. Increased axial and radial depth of cut not only increase material removal rate but also increase the portion of machine tool’s power consumption dedicated to material cutting. This study indicated that 82% reduction in energy consumption can be achieved through precise selection of cutting
parameters.