A novel energy evaluation approach of machining processes based on data analysis

ABSTRACT

Energy shortages, air pollution, and stringent environmental requirements have been gaining increasing concern. Since the scarcity of energy resources, it is imperative to consider the economic and environmental issues of growth in manufacturing. This paper presented an energy evaluation method (considering cutting edges, workpiece hardness, material removal rate, and rotation speed) for machining system based on the group method of data handling (GMDH) algorithm. First, a response surface experimental was carried out with three materials to determine whether the cutting edges, workpiece hardness, spindle speed, and material removal rate (MRR) affect the processing energy. It was concluded that cutting edges number and hardness obviously have a significant influence on energy consumption. Then, further experimentations were designed, and an evaluation model of the electrical energy demand based on GMDH algorithm has been proposed, in which the application in a milling machine tool indicates that the predicted output values were found to correlate closely with the measured values. Finally, the proposed model is applied to a workpiece machining process, and the results show that the approach presented in this paper is effective, and hence, this paper provides an important addition to existing machining processes energy-evaluating methods.

KEYWORDS:

• Energy evaluation
• cutting edges
• workpiece hardness
• machining processes
• Group method of data handling (GMDH)

Additional information

Funding

This work was supported by the National Natural Science Foundation of China [51775392]; Key Laboratory of Automotive Power Train and Electronics (Hubei University of Automotive Technology) [ZDK1201802]; Hubei Key Laboratory of Mechanical Transmission and Manufacturing Engineering at Wuhan University of Science and Technology [MTMEOF2019B08].

Notes on contributors

Ma Feng

Ma Feng  Lecturer in the School of Mechanical Engineering, Wuhan University of Science & Technology, Wuhan, China. His current research interests include green manufacturing and manufacturing system energy efficiency.

Zhang Hua

Zhang Hua Professor in the School of Mechanical Engineering, Wuhan University of Science & Technology, Wuhan, China. His current research interests include green manufacturing and sustainable manufacturing.

Gong Qingshan

Gong Qingshan Lecturer in the School of Mechanical Engineering, Hubei University of Automotive Technology, ShiYan, China. His current research interests include green manufacturing and sustainable design.

K.K.B. Hon

K.K.B. Hon Professor in University of Liverpool, Liverpool, Britain. His current research interests include sustainable manufacturing and sustainable design.