Machine-Specific Estimation of Milling Energy Consumption in Detailed Design

2021 ◽  
pp. 1-24
Author(s):  
Till Boettjer ◽  
Johan Krogshave ◽  
Devarajan Ramanujan
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Design Stage ◽  
Total Energy Consumption ◽  
Estimation Errors ◽  
Workpiece Material ◽  
Detailed Design ◽  
Energy Estimation ◽  
Unit Process

Abstract Manufacturing is a significant contributor to global greenhouse gas emissions and there is an urgent need to reduce the energy consumption of production processes. An important step towards this goal is proactively estimating process energy consumption at the detailed design stage. This is a challenging task as variabilities in factors such as process specifications, machine tool architecture, and workpiece geometry can significantly reduce the accuracy of the estimated energy consumption. This paper discusses a methodology for machine-specific energy estimation in milling processes at the detailed design stage based on the unit process life cycle inventory (UPLCI) model. We develop an adjusted UPLCI model that includes adjustment factors for uncertainties in machine tool specifications and the specific cutting energy of a workpiece material. To validate the adjusted UPLCI model, we conducted a case study that measured the energy consumption for machining three parts made of Aluminum 6082 on two separate three-axis vertical milling machines, a Chevalier QP2040-L and a Leadwell MCV-OP. Results show that the UPLCI model consistently overestimated the total energy consumption for machining the three validation parts across both machine tools. We also found the adjusted UPLCI model significantly reduced the estimation errors for the same tests for both machine tools.

Machine-Specific Energy Estimation Using the Unit Process Life Cycle Inventory (UPLCI) Model

2020 ◽  
Author(s):  
Johan Thoft Krogshave ◽  
Till Boettjer ◽  
Devarajan Ramanujan
Keyword(s):  
Life Cycle ◽  
Energy Consumption ◽  
Machine Tool ◽  
Specific Energy ◽  
Life Cycle Inventory ◽  
Estimation Errors ◽  
Workpiece Material ◽  
Energy Estimation ◽  
Unit Process ◽  
Adjustment Factors

Abstract This paper discusses a method for machine-specific energy estimation in milling processes using the unit process life cycle inventory (UPLCI) model. To this end, we develop a standard methodology for constructing an adjusted UPLCI model that includes adjustment factors for uncertainties in machine tool specifications and the specific cutting energy of a workpiece material. The adjustment factors are calculated through experimental measurement of energy consumption for a standard test part on a specific machine tool. To validate the adjusted UPLCI model, we conducted a case study which experimentally measured the energy consumption for machining three parts made of Aluminum 6082 on a Chevalier QP2040-L three-axis vertical milling machine. Results show that the UPLCI model consistently overestimated the total energy consumption for machining the three parts and had significant estimation errors (314%, 499%, 286%). The largest sources of error in the UPLCI model were from overestimating the idle and basic power consumption of the machine tool. The adjusted UPLCI model significantly reduced the estimation errors for the same tests (27%, 0.3%, 36%).

A Simplified Machine-Tool Power-Consumption Measurement Procedure and Methodology for Estimating Total Energy Consumption

2015 ◽  
Vol 138 (5) ◽  
Author(s):  
Jang-Yeob Lee ◽  
Yong-Jun Shin ◽  
Min-Soo Kim ◽  
Eun-Seob Kim ◽  
Hae-Sung Yoon ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Total Energy ◽  
Machine Tools ◽  
Measurement Procedure ◽  
Single Model ◽  
Total Energy Consumption ◽  
Cutting Energy ◽  
Energy Consumption Model ◽  
Consumption Model

Various methods have been developed to describe the energy consumption of machine tools; however, it remains challenging to accommodate the wide variety of machine tools that exist using a single model. In this paper we propose a method to model the energy consumption of machine tools by decoupling the energy of the components of the machine tool from the cutting energy. A procedure is developed to describe the characteristics of the energy consumption of machine tools, which is applied to six different machines. The experimental results show that the cutting energy can be decoupled from the component energy. In this manner, a simplified energy consumption model is developed that can be applied to a wide variety of different machine tools.

scholarly journals A Systematic Methodology for Accurate Design-Stage Estimation of Energy Consumption for Injection Molded Parts

2010 ◽  
Author(s):  
Alexander Weissman ◽  
Arvind Ananthanarayanan ◽  
Satyandra K. Gupta ◽  
Ram D. Sriram
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Product Design ◽  
Flow Simulation ◽  
Setup Time ◽  
Analytical Models ◽  
Design Stage ◽  
Limited Information ◽  
Energy Estimation ◽  
Time Required

Today’s ubiquitous use of plastics in product design and manufacturing presents significant environmental and human health challenges. Injection molding, one of the most commonly used processes for making plastic products, consumes a significant amount of energy. A methodology for accurately estimating the energy consumed to injection-mold a part would enable environmentally conscious decision making during the product design. Unfortunately, only limited information is available at the design stage. Therefore, accurately estimating energy consumption before the part has gone into production can be challenging. In this paper, we describe a methodology for energy estimation that works with the limited amount of data available during the design stage, namely the CAD model of the part, the material name, and the production requirements. The methodology uses this data to estimate the parameters of the runner system and an appropriately sized molding machine. It then uses these estimates to compute the machine setup time and the cycle time required for the injection molding operation. This is done by appropriately abstracting information available from the mold flow simulation tools and analytical models that are traditionally used during the manufacturing stage. These times are then multiplied by the power consumed by the appropriately sized machine during each stage of the molding cycle to compute the estimated energy consumption per part.

scholarly journals Regular Neural Network Based Machining Parameters Optimization Model Of NC Machine Tool

2018 ◽  
Vol 232 ◽  
pp. 01006
Author(s):  
Sanping Wang ◽  
Junwen Chen ◽  
Wei Yan
Keyword(s):  
Neural Network ◽  
Energy Efficiency ◽  
Energy Consumption ◽  
Machine Tool ◽  
Process Parameters ◽  
Machine Tools ◽  
Machining Process ◽  
Machining Parameters ◽  
Nc Machine Tool ◽  
Nc Machine

Energy consumption process is the basis for energy efficiency improvement of machine tools. Most of the existing researches focus on the static modelling of energy consumption of a machine tool; however, there are a few studies that paid attention to that how process parameters influence the energy consumption of machine tools during processing. It is noted that the process parameters can be selected to reduce energy consumption during machining processes without additional investment. In this paper, a characteristic energy consumption model for NC machine tool was proposed. Then, the mapping rule between process parameters and energy consumption of machine tool was studied, and the model was solved with the regular neural network (RNN). Finally, the result was verified with an experiment of milling the surface of aluminium block, which can effectively improve the energy efficiency of machine tool. The experiment results are shown that regular neural network is used to optimize the process parameters and process the same machining characteristics; we analyze the in machining process of machine tool based on the three cutting parameters, and then, a model of energy consumption. We employ to learn, and use this trained model to select optimal parameters.

Genetic Optimization for the Design of a Machine Tool Slide Table for Reduced Energy Consumption

2021 ◽  
Vol 143 (10) ◽  
Author(s):  
Matthew J. Triebe ◽  
Fu Zhao ◽  
John W. Sutherland
Keyword(s):  
Genetic Algorithm ◽  
Finite Element ◽  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Sandwich Panel ◽  
Sustainable Manufacturing ◽  
Element Model ◽  
Genetic Optimization ◽  
Use Phase

Abstract Reducing the energy consumption of machine tools is important from a sustainable manufacturing perspective. Much of a machine tool’s environmental impact comes from the energy it consumes during its use phase. To move elements of a machine tool requires energy, and if the mass of those elements can be reduced, then the required energy would be reduced. Therefore, this paper proposes a genetic algorithm to design lightweight machine tools to reduce their energy consumption. This is specifically applied to optimize the structure of a machine tool slide table, which moves throughout the use of the machine tool, with the goal of reducing its mass without sacrificing its stiffness. The table is envisioned as a sandwich panel, and the proposed genetic algorithm optimizes the core of the sandwich structure while considering both mass and stiffness. A finite element model is used to assess the strength of the proposed designs. Finite element results indicate that the strength of the lightweight tables is comparable with a traditional table design.

Approach to Forecast Energy Consumption of Machine Tools within the Design Phase

2013 ◽  
Vol 769 ◽  
pp. 278-284 ◽  
Author(s):  
Karl Doreth ◽  
Jan Henjes ◽  
Stefan Kroening
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Production Systems ◽  
Design Phase ◽  
Empirical Information ◽  
Complex Simulation ◽  
Data Feedback ◽  
Acquisition Costs

For environmental and economic reasons, energy- and resource- efficient operations of cutting machines are increasingly important. The determination of properties and functions of machine tools, which affect future energy consumption in operation, essentially takes place within the design phase by combining required components. Therefore, it is necessary to develop approaches to find an efficient optimum between energy consumption, productivity, acquisition costs and operating costs within the design phase of a machine tool. However, the energy consumption of a machine tool depends on the application scenario. In addition to that, it is difficult to forecast the energy consumption of several components because of their mutual interaction. Existing approaches to forecast the energy consumption of a machine tool within design phase are based on complex simulation or mathematical models which are difficult to parameterize for the design of a machine tool and thus, for the comparison of various configuration alternatives. An alternative for forecasting energy consumption is the use of empirical information. That information can be acquired by measuring the energy consumption of machine tools in operating production systems. This paper presents an approach to forecast the energy consumption of machine tools within the design phase, which will be developed by the Institute of Production Engineering and Machine Tools. It will be based on the data feedback (empirical information) from a machine tool operating in an existing manufacturing system. For this purpose, a logger module will be developed, which continually captures the energy consumption by means of the machine integrated sensors. That information will be sent back to an energy navigator module, which processes that information in order to forecast the energy consumption of a new designed machine tool. Also, the lifecycle costs will be calculated in order to rate cost and benefits of each machines lifecycle in terms of energy consumption.

scholarly journals An Exhaustive Search Energy Optimization Method for Residential Building Envelope in Different Climatic Zones of Kazakhstan

Buildings ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 633
Author(s):  
Mirzhan Kaderzhanov ◽  
Shazim Ali Memon ◽  
Assemgul Saurbayeva ◽  
Jong R. Kim
Keyword(s):  
Energy Consumption ◽  
Energy Savings ◽  
Residential Buildings ◽  
Average Energy ◽  
Optimization Method ◽  
Building Envelope ◽  
Energy Reduction ◽  
Estimation Model ◽  
Total Energy Consumption ◽  
Energy Estimation

Nowadays, the residential sector of Kazakhstan accounts for about 30% of the total energy consumption. Therefore, it is essential to analyze the energy estimation model for residential buildings in Kazakhstan so as to reduce energy consumption. This research is aimed to develop the Overall Thermal Transfer Value (OTTV) based Building Energy Simulation Model (BESM) for the reduction of energy consumption through the envelope of residential buildings in seven cities of Kazakhstan. A brute force optimization method was adopted to obtain the optimal envelope configuration varying window-to-wall ratio (WWR), the angle of a pitched roof, the depth of the overhang shading system, the thermal conductivity, and the thicknesses of wall composition materials. In addition, orientation-related analyses of the optimized cases were conducted. Finally, the economic evaluation of the base and optimized cases were presented. The results showed that an average energy reduction for heating was 6156.8 kWh, while for cooling it was almost 1912.17 kWh. The heating and cooling energy savings were 16.59% and 16.69%, respectively. The frontage of the building model directed towards the south in the cold season and north in the hot season demonstrated around 21% and 32% of energy reduction, respectively. The energy cost savings varied between 9657 to 119,221 ₸ for heating, 9622 to 36,088 ₸ for cooling.

scholarly journals AVALIAÇÃO DO CICLO DE VIDA ENERGÉTICO (ACVE) E DO DESEMPENHO TÉRMICO DE UMA HABITAÇÃO DE LIGHT STEEL FRAMING COM O USO DE DIFERENTES TIPOS DE ISOLANTES TÉRMICOS

2016 ◽  
Vol 11 (2) ◽  
Author(s):  
Lucas Rosse Caldas ◽  
Rosa Maria Sposto ◽  
Alexandre Mendonça Souto Lopes ◽  
Werner Castro Tavares
Keyword(s):  
Life Cycle ◽  
Energy Consumption ◽  
Thermal Insulation ◽  
Thermal Performance ◽  
Simulation Software ◽  
Embodied Energy ◽  
Design Stage ◽  
International Studies ◽  
Total Energy Consumption ◽  
Steel Framing

RESUMO: Como forma de mensurar o consumo de energia ao longo do ciclo de vida dos diversos sistemas construtivos existentes, entre eles o light steel framing (LSF), tem sido aplicado a avaliação do ciclo de vida energético (ACVE). A ACVE foi aplicada em diversos estudos nacionais e internacionais, e no caso do LSF já foi verificado em alguns estudos nacionais. No entanto, ainda existe uma lacuna de estudos relacionados com o desempenho térmico e com os isolantes térmicos utilizados, principalmente por meio de simulações termoenergéticas. Neste sentido, o presente trabalho teve como objetivo avaliar a energia consumida ao longo do ciclo de vida de uma habitação de LSF, comparando o desempenho térmico deste sistema sem e com três isolantes térmicos, sendo eles: lã de vidro, lã de rocha e poliestireno expandido (EPS). A metodologia utilizada foi a pesquisa bibliográfica e simulação computacional em um software de simulação termoenergético. Ao final foi levantada a energia incorporada dos materiais utilizados nas fachadas, energia consumida nos transportes e energia gasta pelos equipamentos eletrônicos (energia operacional). A soma de todos estes consumos resultou na energia total, esta que foi maior para o sistema sem isolamento térmico e menor para o sistema com EPS. Neste sentido, a principal contribuição deste trabalho foi apresentar um critério de sustentabilidade energética para a especificação de isolantes térmicos para o sistema de LSF. Este critério poderá subsidiar, durante a etapa de projeto, a escolha do sistema mais vantajoso tanto do ponto de vista térmico como do consumo de energia ao longo do ciclo de vida da edificação. ABSTRACT: As a way to measure the energy consumption over the life cycle of the various existing building systems, including light steel framing (LSF), has been applied to evaluate the life cycle energy assessment (LCEA). The LCEA was applied in several national and international studies, and in the case of LSF has already been verified in some national studies. However, there is still a lack of research related to thermal performance and thermal insulation used, mainly through thermal-energetic simulations. In this context, this study aimed to evaluate the energy consumed throughout the life cycle of a LSF house, comparing the thermal performance of this system without and with three thermal insulations, which are: glass wool, rock wool and polystyrene expanded (EPS). The methodology used was the bibliographical research and computer simulation on a thermal-energetic simulation software. It was assessed the embodied energy of the materials used on the facades, energy consumed in transport and energy consumed by electronic equipment (operating energy). The sum of all these resulted in total energy consumption, this one was higher for the system without thermal insulation and lower to the system with EPS. In this sense, the main contribution of this paper is to present an energy sustainability criteria for the specification of thermal insulation for the LSF system. This criteria can support, during the design stage, the choice of the most advantageous system in terms of the thermal performance and the energy consumption throughout the life cycle of the building.

scholarly journals Toward a Generalized Energy Prediction Model for Machine Tools

2016 ◽  
Vol 139 (4) ◽  
Author(s):  
Raunak Bhinge ◽  
Jinkyoo Park ◽  
Kincho H. Law ◽  
David A. Dornfeld ◽  
Moneer Helu ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Prediction Model ◽  
Machine Tool ◽  
Process Planning ◽  
Machine Tools ◽  
Prediction Models ◽  
Machining Process ◽  
Data Driven ◽  
Process Data ◽  
Energy Prediction

Energy prediction of machine tools can deliver many advantages to a manufacturing enterprise, ranging from energy-efficient process planning to machine tool monitoring. Physics-based energy prediction models have been proposed in the past to understand the energy usage pattern of a machine tool. However, uncertainties in both the machine and the operating environment make it difficult to predict the energy consumption of the target machine reliably. Taking advantage of the opportunity to collect extensive, contextual, energy-consumption data, we discuss a data-driven approach to develop an energy prediction model of a machine tool in this paper. First, we present a methodology that can efficiently and effectively collect and process data extracted from a machine tool and its sensors. We then present a data-driven model that can be used to predict the energy consumption of the machine tool for machining a generic part. Specifically, we use Gaussian process (GP) regression, a nonparametric machine-learning technique, to develop the prediction model. The energy prediction model is then generalized over multiple process parameters and operations. Finally, we apply this generalized model with a method to assess uncertainty intervals to predict the energy consumed by any part of the machine using a Mori Seiki NVD1500 machine tool. Furthermore, the same model can be used during process planning to optimize the energy-efficiency of a machining process.

Improving the efficiency of surface-thermal hardening of machine parts in conditions of combination of processing technologies, integrated on a single machine tool base

2021 ◽  
Vol 23 (3) ◽  
pp. 45-71
Author(s):  
Vadim Skeeba ◽  
◽  
Vladimir Ivancivsky ◽  
Keyword(s):  
Surface Layer ◽  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Energy Sources ◽  
Technological Equipment ◽  
Thermal Hardening ◽  
Processing Technologies ◽  
Machine Parts ◽  
Hybrid Machine

Introduction. In the manufacturing industry, there is a particular interest in the development of a new type of technological equipment, which makes it possible to implement methods for modifying the parts surface layers by processing it with concentrated energy sources. The combination of two processing technologies (mechanical and surface-thermal operations) in the conditions of integrated equipment makes it possible to neutralize the disadvantages of monotechnologies and obtain new effects that are unattainable when using technologies separately. The use of hybrid machine tools in conjunction with the developed technological recommendations will allow achieving a multiple increase in the technical and economic efficiency of production, resource and energy saving, which in turn will contribute to an increase in the competitiveness of products and the renewal of the technological paradigm. Purpose of work: increasing productivity and reducing energy consumption during surface-thermal hardening of machine parts by exposure to concentrated energy sources under conditions of integrated processing. Theory and methods: studies of the possible structural composition and layout of hybrid equipment during the integration of mechanical and surface-thermal processes are carried out taking into account the main provisions of structural synthesis and the components of metalworking systems. Theoretical studies are carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, finite-element method, mathematical and computer simulation. Mathematical simulation of thermal fields and structural-phase transformations in the case of HEH HFC is carried out in the ANSYS and SYSWELD software packages, using numerical methods for solving the differential equations of unsteady thermal conductivity (Fourier's equation), carbon diffusion (Fick's second law), and elastoplastic behavior of the material. The verification of the simulation results is carried out by conducting field experiments using: optical and scanning microscopy; mechanical and X-ray methods for determining residual stresses. In the study, Uone JD520 and Form Talysurf Series 2 profilograph-profilometers are used to simultaneously measure shape deviations, waviness and surface roughness. Surface topography is assessed using a Zygo New View 7300 laser profilograph-profilometer. The microhardness of the hardened surface layer of parts is evaluated on a Wolpert Group 402MVD device. Results and discussion. An original method of structural-kinematic analysis for pre-design research of hybrid metalworking equipment is presented. Methodological recommendations are developed for the modernization of metal-cutting machine tools, the implementation of which will allow the implementation of high-energy heating by high-frequency currents (HEH HFC) on a standard machine-tool system and ensure the formation of high-tech technological equipment with expanded functionality. A unified integral parameter of the temperature-time effect on a structural material is proposed when the modes of hardening by concentrated heating sources are assigned, which guarantee the required set of quality indicators of the surface layer of machine parts, while ensuring energy efficiency and processing productivity in general. It is experimentally confirmed that the introduction into production of the proposed hybrid machine tool in conjunction with the developed recommendations for the purpose of the HEH HFC modes in the conditions of integral processing of a “Plunger bushing” type part in relation to the factory technology allows increasing the productivity of surface hardening by 3.5 ... 4.1 times, and reduce energy consumption by 9.5 ... 11.3 times.

Sign in / Sign up

Export Citation Format

Share Document