Toward Energy Footprint Reduction of a Machining Process

In a machining process, proper selection of process plans and cutting parameters can effectively reduce energy consumption and shorten production time. Traditionally, studies on process planning and cutting parameter optimization for energy saving are mostly concentrated on electrical energy consumption. Since the preparation process of cutting tools and cutting fluid consumes a considerable amount of energy, conservation of this part of energy consumption, namely, the embodied energy consumption, will achieve a more energy-efficient machining process. In this article, an integrated model for process planning and cutting parameter optimization is proposed to shorten production time and reduce the energy footprint (namely, electrical energy consumption and embodied energy consumption of cutting tools and cutting fluid) of a machining process. Considering that the optimization of process plan and cutting parameters in an integrated manner is a hybrid programming process, simulated annealing and quantum-behaved particle swarm optimization (SA-QPSO) hybrid algorithm is employed to solve the proposed model. Results of the case study show that: 1) embodied energy consumption of cutting tools and cutting fluid accounts for a nonnegligible proportion of energy footprint of the machining process and 2) there is a tradeoff between energy footprint and production time, and the balance of them is achieved through the proposed optimization approach.