Energy characterization and energy-saving strategies in sustainable machining processes: A state-of-the-art review

Authors

  • Aqib Mashood Khan College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China
  • Ning He College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China
  • Muhammad Jamil College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China
  • Syed Muhammad Raza Department of Industrial Engineering, University of Engineering and Technology, Taxila, 47050 Pakistan

Keywords:

Sustainable machining;, Energy efficient machining, Green machining, Difficult-to-cut materials, Energy modelling, Energy consumption

Abstract

A growing number of manufacturing industries are gradually shifting towards sustainable and clean manufacturing due to its raising demand in production cost, energy consumption and environmental pollution. Hence, concern about energy-efficient and environmentally benign manufacturing process have become an emerging issue. This review paper suggests state of the art energy characterization and energy-saving strategies in the manufacturing processes. Sustainable machining processes are discussed according to the application of various coolants/lubricants. Energy consumption was classified according to machine tool components, functionality states of machine tool, and levels of the manufacturing process. Theories and technologies in the assessment and modelling of energy characteristics were reviewed, and general energy-saving strategies were discussed at the assessment level, software-based optimization level, and cutting level. Besides, energy consumption models were discussed. Reducing resource-based energy consumption in machining processes helps in (1) environmental evolution of machine tools (ISO14955-1) (2) tool condition monitoring (3) establishing energy-efficient machining process, and (4) designing new machine tool structure.

References

A.Rangarajan and D. Dornfeld. 2004. “Efficient Tool Paths and Part Orientation for Face Milling.” CIRP Annals - Manufacturing Technology. 53(1), 73-76.
Abas, Muhammad, Lal Sayd, Rehman Akhtar, Qazi Salman Khalid, Aqib Mashood Khan, and Catalin Iulian Pruncu. 2020. “Optimization of Machining Parameters of Aluminum Alloy 6026-T9 under MQL-Assisted Turning Process.” Journal of Materials Research and Technology. 9(5), 10916-10940.
Abdul Sani, Amiril Sahab, Erween Abd Rahim, Safian Sharif, and Hiroyuki Sasahara. 2019. “Machining Performance of Vegetable Oil with Phosphonium- and Ammonium-Based Ionic Liquids via MQL Technique.” Journal of Cleaner Production 209:947–64.
Abellan-Nebot, Jose Vicente and Fernando Romero Subirón. 2010. “A Review of Machining Monitoring Systems Based on Artificial Intelligence Process Models.” International Journal of Advanced Manufacturing Technology. 47(1-4), 237-257.
Alborz Shokrani, Vimal Dhokia, Stephen T. Newma. 2017. “Hybrid Cooling and Lubricating Technology for CNC Milling of Inconel 718 Nickel Alloy.” Procedia Manufacturing 11:625–32.
Ali, Raneen Abd, Mozammel Mia, Aqib Mashood Khan, Wenliang Chen, Munish Kumar Gupta, and Catalin Iulian Pruncu. 2019. “Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024.” Materials. 12(7), 1013.
Alt?parmak, S.C. 2018. “Analysis of Thermal Expansion and Micro-Delamination Phenomenon of Cutting Tool Thin Surface Coatings in High-Speed Dry Machining.” K?rklareli Üniversitesi Mühendislik ve Fen Bilimleri Dergisi 4(2):189–211.
Alt?parmak, S.C. 2019. “Effects of Thermal Expansion Coefficient on Micro-Delamination and Thermal Expansion of Coated and Uncoated Tungsten Carbide Cutting Tools in High Speed Machining.” Research & Reviews in Engineering:25-40.
Alves, Sm and Jfg De Oliveira. 2008. “Vegetable Based Cutting Fluid–an Environmental Alternative to Grinding Process.” 15th CIRP International Conference on Life Cycle Engineering CIRP.. (p. 664-671).
Amer, W., R. I. Grosvenor, and P. W. Prickett. 2006. “Sweeping Filters and Tooth Rotation Energy Estimation (TREE) Techniques for Machine Tool Condition Monitoring.” International Journal of Machine Tools and Manufacture. 46(9), 1045-1052.
Anderberg, S. E., S. Kara, and T. Beno. 2010. “Impact of Energy Efficiency on Computer Numerically Controlled Machining.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 224(4):531–41.
Aurich, J. C., B. Linke, M. Hauschild, M. Carrella, and B. Kirsch. 2013. “Sustainability of Abrasive Processes.” CIRP Annals - Manufacturing Technology. 62(2), 653-672.
Avram, Oliver Ioan and Paul Xirouchakis. 2011. “Evaluating the Use Phase Energy Requirements of a Machine Tool System.” Journal of Cleaner Production. 19(6-7), 699-711.
Balogun, Vincent A., Isuamfon F. Edem, Adefemi A. Adekunle, and Paul T. Mativenga. 2016. “Specific Energy Based Evaluation of Machining Efficiency.” Journal of Cleaner Production. 116, 187-197.
Balogun, Vincent Aizebeoje, Isuamfon F. Edem, Heng Gu, and Paul Tarisai Mativenga. 2018. “Energy Centric Selection of Machining Conditions for Minimum Cost.” Energy. 164, 655-663.
Balogun, Vincent Aizebeoje and Paul Tarisai Mativenga. 2013a. “Modelling of Direct Energy Requirements in Mechanical Machining Processes.” Journal of Cleaner Production 41:179–86.
Balogun, Vincent Aizebeoje and Paul Tarisai Mativenga. 2013b. “Modelling of Direct Energy Requirements in Mechanical Machining Processes.” Journal of Cleaner Production 41:179–86.
Behrendt, Thomas, André Zein, and Sangkee Min. 2012. “Development of an Energy Consumption Monitoring Procedure for Machine Tools.” CIRP Annals - Manufacturing Technology. 61(1), 43-46.
Bhushan, Rajesh Kumar. 2013. “Optimization of Cutting Parameters for Minimizing Power Consumption and Maximizing Tool Life during Machining of Al Alloy SiC Particle Composites.” Journal of Cleaner Production. 39, 242-254.
Brecher, Christian, Johannes Triebs, and David Jasper. 2013. “Energy Efficient Solutions for Hydraulic Units of Machine Tools.” in Re-Engineering Manufacturing for Sustainability - Proceedings of the 20th CIRP International Conference on Life Cycle Engineering. 2013. 191-196.
Byrne, G., D. Dornfeld, I. Inasaki, G. Ketteler, W. König, and R. Teti. 1995. “Tool Condition Monitoring (TCM) - The Status of Research and Industrial Application.” CIRP Annals - Manufacturing Technology. 44(2), 541-567.
Byrne, G. and E. Scholta. 1993. “Environmentally Clean Machining Processes - A Strategic Approach.” CIRP Annals - Manufacturing Technology. 42(1), 471-474.
Cagno, Enrico and Andrea Trianni. 2013. “Exploring Drivers for Energy Efficiency within Small- and Medium-Sized Enterprises: First Evidences from Italian Manufacturing Enterprises.” Applied Energy. 104, 276-285.
Camposeco-Negrete, Carmita. 2013. “Optimization of Cutting Parameters for Minimizing Energy Consumption in Turning of AISI 6061 T6 Using Taguchi Methodology and ANOVA.” Journal of Cleaner Production. 53, 195-203.
Courbon, C., F. Pusavec, F. Dumont, J. Rech, and J. Kopac. 2013. “Tribological Behaviour of Ti6Al4V and Inconel718 under Dry and Cryogenic Conditions - Application to the Context of Machining with Carbide Tools.” Tribology International. 66, 72-82.
Dahmus, Jeffrey B. and Timothy G. Gutowski. 2004. “An Environmental Analysis of Machining.” Manufacturing Engineering and Materials Handling Engineering 2004:643–52.
Denkena, Berend, Patrick Helmecke, and Lars Hülsemeyer. 2015. “Energy Efficient Machining of Ti-6Al-4V.” CIRP Annals - Manufacturing Technology. 64(1), 61-64.
Devillez, A., G. Le Coz, S. Dominiak, and D. Dudzinski. 2011. “Dry Machining of Inconel 718, Workpiece Surface Integrity.” Journal of Materials Processing Technology. 211(10), 1590-1598.
Dhananchezian, M. and M. Pradeep Kumar. 2011. “Cryogenic Turning of the Ti-6Al-4V Alloy with Modified Cutting Tool Inserts.” Cryogenics. 51(1), 34-40.
Dhar, N. R., M. W. Islam, S. Islam, and M. A. H. Mithu. 2006. “The Influence of Minimum Quantity of Lubrication (MQL) on Cutting Temperature, Chip and Dimensional Accuracy in Turning AISI-1040 Steel.” Journal of Materials Processing Technology 171:93–99.
Diaz, Nancy, Seungchoun Choi, Moneer Helu, Yien Yifen Chen, Stephen Jayanathan, Yusuke Yasui, Daeyoung Kong, Sushrut Pavanaskar, and David Dornfeld. 2010. “Machine Tool Design and Operation Strategies for Green Manufacturing.” Proceedings of 4th CIRP International Conference on High Performance Cutting, 2010.
Diaz, Nancy, Elena Redelsheimer, and David Dornfeld. 2011. “Energy Consumption Characterization and Reduction Strategies for Milling Machine Tool Use.” in Glocalized Solutions for Sustainability in Manufacturing - Proceedings of the 18th CIRP International Conference on Life Cycle Engineering.
Dietmair, A. and A. Verl. 2009. “ENERGY CONSUMPTION FORECASTING AND OPTIMISATION FOR TOOL MACHINES.” MM Science Journal. 62, 63.
Dietmair, Anton and Alexander Verl. 2008. “Energy Consumption Modeling and Optimization for Production Machines.” in 2008 IEEE International Conference on Sustainable Energy Technologies, ICSET 2008. (pp. 574-579). IEEE.
Dornfeld, David Alan. 2014. “Moving towards Green and Sustainable Manufacturing.” International Journal of Precision Engineering and Manufacturing - Green Technology. 1(1), 63-66.
Dudzinski, D., A. Devillez, A. Moufki, D. Larrouquère, V. Zerrouki, and J. Vigneau. 2004. “A Review of Developments towards Dry and High Speed Machining of Inconel 718 Alloy.” International Journal of Machine Tools and Manufacture. 44(4), 439-456.
Duflou, Joost R., John W. Sutherland, David Dornfeld, Christoph Herrmann, Jack Jeswiet, Sami Kara, Michael Hauschild, and Karel Kellens. 2012. “Towards Energy and Resource Efficient Manufacturing: A Processes and Systems Approach.” CIRP Annals - Manufacturing Technology. 61(2), 587-609.
EIA. 2013. International Energy Outlook 2013 US Energy Inf. Adminis- Tration 312.
Elshwain, A. E. I. and Norizah Redzuan. 2013. “Effect of Cooling/Lubrication Using Cooled Air, MQL + Cooled Air, N2 and CO2 Gases on Tool Life and Surface Finish in Machining – A Review.” Advanced Materials Research 845:889–93.
Fratila, Domnita. 2009. “Evaluation of Near-Dry Machining Effects on Gear Milling Process Efficiency.” Journal of Cleaner Production. 17(9), 839-845.
Fratila, Domnita. 2010. “Macro-Level Environmental Comparison of near-Dry Machining and Flood Machining.” Journal of Cleaner Production. 18(10-11), 1031-1039.
Gajrani, Kishor Kumar, Rokkham Pavan Kumar Reddy, and Mamilla Ravi Sankar. 2019. “Tribo-Mechanical and Surface Morphological Comparison of Untextured, Mechanical Micro-Textured (M?T), and Coated-M?T Cutting Tools during Machining.” Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology. 233(1), 95-111.
Gajrani, Kishor Kumar, Dhanna Ram, and Mamilla Ravi Sankar. 2017. “Biodegradation and Hard Machining Performance Comparison of Eco-Friendly Cutting Fluid and Mineral Oil Using Flood Cooling and Minimum Quantity Cutting Fluid Techniques.” Journal of Cleaner Production. 165, 1420-1435.
Gajrani, Kishor Kumar, P. S. Suvin, Satish Vasu Kailas, and Ravi Sankar Mamilla. 2019. “Thermal, Rheological, Wettability and Hard Machining Performance of MoS2 and CaF2 Based Minimum Quantity Hybrid Nano-Green Cutting Fluids.” Journal of Materials Processing Technology. 266, 125-139.
Gong, Le, Wei Zhao, Fei Ren, Ning He, Liang Li, Qing Xu, and Aqib Mashood Khan. 2019. “Experimental Study on Surface Integrity in Cryogenic Milling of 35CrMnSiA High-Strength Steel.” International Journal of Advanced Manufacturing Technology. 103(1-4), 605-615.
Götze, U., H. J. Koriath, A. Kolesnikov, R. Lindner, and J. Paetzold. 2012. “Integrated Methodology for the Evaluation of the Energy- and Cost-Effectiveness of Machine Tools.” CIRP Journal of Manufacturing Science and Technology. 5(3), 151-163.
Gupta, Kapil, R. F. Laubscher, J. Paulo Davim, and N. K. Jain. 2016. “Recent Developments in Sustainable Manufacturing of Gears: A Review.” Journal of Cleaner Production 112:3320–30.
Gupta, Munish Kumar, Muhammad Jamil, Xiaojuan Wang, Qinghua Song, Zhanqiang Liu, Mozammel Mia, Hussein Hegab, Aqib Mashood Khan, Alberto Garcia Collado, Catalin Iulian Pruncu, and G. M. Sha. Imran. 2019. “Performance Evaluation of Vegetable Oil-Based Nano-Cutting Fluids in Environmentally Friendly Machining of Inconel-800 Alloy.” Materials. 172, 2862-2875.
Gupta, Munish Kumar, Mozammel Mia, Muhammad Jamil, Rupinder Singh, Anil Kumar Singla, Qinghua Song, Zhanqiang Liu, Aqib Mashood Khan, M. Azizur Rahman, and Murat Sarikaya. 2020. “Machinability Investigations of Hardened Steel with Biodegradable Oil-Based MQL Spray System.” International Journal of Advanced Manufacturing Technology. 72, 862-875.
Gupta, Munish Kumar, Qinghua Song, Zhanqiang Liu, Murat Sarikaya, Muhammad Jamil, Mozammel Mia, Navneet Khanna, and Grzegorz M. Krolczyk. 2021. “Experimental Characterisation of the Performance of Hybrid Cryo-Lubrication Assisted Turning of Ti–6Al–4V Alloy.” Tribology International. 106582.
Gupta, Munish Kumar, Qinghua Song, Zhanqiang Liu, Murat Sarikaya, Muhammad Jamil, Mozammel Mia, Vinod Kushvaha, Anil Kumar Singla, and Zhixiong Li. 2020. “Ecological, Economical and Technological Perspectives Based Sustainability Assessment in Hybrid-Cooling Assisted Machining of Ti-6Al-4 V Alloy.” Sustainable Materials and Technologies 4(2) 218-233
Gupta, Munish Kumar, P. K. Sood, and Vishal S. Sharma. 2016. “Optimization of Machining Parameters and Cutting Fluids during Nano-Fluid Based Minimum Quantity Lubrication Turning of Titanium Alloy by Using Evolutionary Techniques.” Journal of Cleaner Production. 135, 1276-1288.
Gupta, Munish Kumar, P. K. Sood, Gurraj Singh, and Vishal S. Sharma. 2018. “Investigations of Performance Parameters in NFMQL Assisted Turning of Titanium Alloy Using TOPSIS and Particle Swarm Optimisation Method.” International Journal of Materials and Product Technology. 57(4), 299-321.
Gutowski, Timothy, Jeffrey Dahmus, and Alex Thiriez. 2006. “Electrical Energy Requirements for Manufacturing Processes.” 13 Th CIRP International Conference of Life Cycle Engineering (Cvd):1–5.
Haapala, Karl R., Fu Zhao, Jaime Camelio, John W. Sutherland, Steven J. Skerlos, David A. Dornfeld, I. S. Jawahir, Andres F. Clarens, and Jeremy L. Rickli. 2013. “A Review of Engineering Research in Sustainable Manufacturing.” Journal of Manufacturing Science and Engineering, Transactions of the ASME. 135, no. 4 (2013).
He, Y., F. Liu, T. Wu, F. P. Zhong, and B. Peng. 2012. “Analysis and Estimation of Energy Consumption for Numerical Control Machining.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 226(2), 255-266.
Hu, Shaohua, Fei Liu, Yan He, and Tong Hu. 2012. “An On-Line Approach for Energy Efficiency Monitoring of Machine Tools.” Journal of Cleaner Production. 27, 133-140.
Huang, Jing, Fei Liu, and Jun Xie. 2016. “A Method for Determining the Energy Consumption of Machine Tools in the Spindle Start-up Process before Machining.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 230(9):1639–49.
Huang, Pan Ling, Jian Feng Li, Jie Sun, and Jun Zhou. 2014. “Study on Performance in Dry Milling Aeronautical Titanium Alloy Thin-Wall Components with Two Types of Tools.” Journal of Cleaner Production. 67, 258-264.
Ic, Yusuf Tansel, Ebru Saralo?lu Güler, Ceren Cabbaro?lu, Ezgi Dilan Yüksel, and Huri Maide Sa?lam. 2018. “Optimisation of Cutting Parameters for Minimizing Carbon Emission and Maximising Cutting Quality in Turning Process.” International Journal of Production Research. 56(11), 4035-4055.
Ingarao, Giuseppe. 2017. “Manufacturing Strategies for Efficiency in Energy and Resources Use: The Role of Metal Shaping Processes.” Journal of Cleaner Production. 142, 2872-2886.
Ingarao, Giuseppe, Hans Vanhove, Karel Kellens, and Joost R. Duflou. 2014. “A Comprehensive Analysis of Electric Energy Consumption of Single Point Incremental Forming Processes.” Journal of Cleaner Production. 67, 173-186.
Iturbe, A., E. Hormaetxe, A. Garay, and P. J. Arrazola. 2016. “Surface Integrity Analysis When Machining Inconel 718 with Conventional and Cryogenic Cooling.” in Procedia CIRP. 45, 67-70
Jamil, Muhammad, Ning He, Liang Li, and Aqib Mashood Khan. 2020. “Clean Manufacturing of Ti-6Al-4V under CO2-Snow and Hybrid Nanofluids.” Procedia Manufacturing. 48, 131-140.
Jamil, Muhammad, Aqib Mashood Khan, Munish Kumar Gupta, Mozammel Mia, Ning He, Liang Li, and VinothKumar Sivalingam. 2020. “Influence of CO2-Snow and Subzero MQL on Thermal Aspects in the Machining of Ti-6Al-4V.” Applied Thermal Engineering 177:115480.
Jamil, Muhammad, Aqib Mashood Khan, Ning He, Liang Li, Asif Iqbal, and Mozammel Mia. 2019. “Evaluation of Machinability and Economic Performance in Cryogenic-Assisted Hard Turning of ?-? Titanium: A Step towards Sustainable Manufacturing.” Machining Science and Technology. 23(6), 1022-1046.
Jamil, Muhammad, Aqib Mashood Khan, Ning He, Liang Li, Wei Zhao, and Shoaib Sarfraz. 2019. “Multi-Response Optimisation of Machining Aluminium-6061 under Eco-Friendly Electrostatic Minimum Quantity Lubrication Environment.” International Journal of Machining and Machinability of Materials. 21(5-6), 459-479.
Jamil, Muhammad, Aqib Mashood Khan, Hussien Hegab, Munish Kumar Gupta, Mozammel Mia, Ning He, Guolong Zhao, Qinghua Song, and Zhanqiang Liu. 2020. “Milling of Ti–6Al–4V under Hybrid Al2O3-MWCNT Nanofluids Considering Energy Consumption, Surface Quality, and Tool Wear: A Sustainable Machining.” International Journal of Advanced Manufacturing Technology. 107(9-10), 4141-4157.
Jeswiet, J. and S. Kara. 2008. “Carbon Emissions and CESTM in Manufacturing.” CIRP Annals - Manufacturing Technology. 57(1), 17-20.
Kalpakjian, Serope, and S. Schmid. 1995. “Manufacturing Engineering and Technology, 6th Eddition.” Addision-Wesley Publishing Company Inc (1992).
Kamata, Y. and T. Obikawa. 2007. “High Speed MQL Finish-Turning of Inconel 718 with Different Coated Tools.” Journal of Materials Processing Technology 192–193:281–86.
Kara, S. and W. Li. 2011a. “Unit Process Energy Consumption Models for Material Removal Processes.” CIRP Annals - Manufacturing Technology. 60(1), 37-40.
Kara, S. and W. Li. 2011b. “Unit Process Energy Consumption Models for Material Removal Processes.” CIRP Annals - Manufacturing Technology 60(1):37–40.
Kaynak, Y., H. E. Karaca, R. D. Noebe, and I. S. Jawahir. 2013. “Analysis of Tool-Wear and Cutting Force Components in Dry, Preheated, and Cryogenic Machining of NiTi Shape Memory Alloys.” in Procedia CIRP. 8 (2013): 498-503.
Kaynak, Yusuf. 2014. “Evaluation of Machining Performance in Cryogenic Machining of Inconel 718 and Comparison with Dry and MQL Machining.” International Journal of Advanced Manufacturing Technology. 72(5-8), 919-933.
Kedare, S. B., D. R. Borse, and P. T. Shahane. 2014. “Effect of Minimum Quantity Lubrication (MQL) on Surface Roughness of Mild Steel of 15HRC on Universal Milling Machine.” Procedia Materials Science 6(Icmpc):150–53.
Kellens, Karel, Wim Dewulf, Michael Overcash, Michael Z. Hauschild, and Joost R. Duflou. 2012. “Methodology for Systematic Analysis and Improvement of Manufacturing Unit Process Life-Cycle Inventory (UPLCI)-CO2PE! Initiative (Cooperative Effort on Process Emissions in Manufacturing). Part 1: Methodology Description.” International Journal of Life Cycle Assessment.
Khaliq, Waqas, Chen Zhang, Muhammad Jamil, and Aqib Mashood Khan. 2020. “Tool Wear, Surface Quality, and Residual Stresses Analysis of Micro-Machined Additive Manufactured Ti–6Al–4V under Dry and MQL Conditions.” Tribology International. 106408- 106419.
Khan, Aqib Mashood, Munish Kumar Gupta, Hussein Hegab, Muhammad Jamil, Mozammel Mia, Ning He, Qinghua Song, Zhanqiang Liu, and Catalin Iulian Pruncu. 2020. “Energy-Based Cost Integrated Modelling and Sustainability Assessment of Al-GnP Hybrid Nanofluid Assisted Turning of AISI52100 Steel.” Journal of Cleaner Production 257:120502.
Khan, Aqib Mashood, Ning He, Liang Li, Wei Zhao, and Muhammad Jamil. 2020. “Analysis of Productivity and Machining Efficiency in Sustainable Machining of Titanium Alloy.” Procedia Manufacturing 43:111–18.
Khan, Aqib Mashood, Muhammad Jamil, Mozammel Mia, Ning He, Wei Zhao, and Le Gong. 2020. “Sustainability-Based Performance Evaluation of Hybrid Nanofluid Assisted Machining.” Journal of Cleaner Production 257:120541.
Khan, Aqib Mashood, Muhammad Jamil, Mozammel Mia, Danil Yurievich Pimenov, Vadim Rashitovich Gasiyarov, Munish Kumar Gupta, and Ning He. 2018. “Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL.” Materials. 11(11), 2269.
Khan, Aqib Mashood, Muhammad Jamil, Ahsan Ul Haq, Salman Hussain, Longhui Meng, and Ning He. 2019. “Sustainable Machining. Modeling and Optimization of Temperature and Surface Roughness in the Milling of AISI D2 Steel.” Industrial Lubrication and Tribology. 435-446
Kim, H. Y., J. H. Ahn, S. H. Kim, and S. Takata. 2002. “Real-Time Drill Wear Estimation Based on Spindle Motor Power.” Journal of Materials Processing Technology. 124(3), 267-273.
Klocke, F. and G. Eisenblaetter. 1997. “Dry Cutting.” CIRP Annals - Manufacturing Technology.
Klocke, F. and G. Eisenblätter. 1997. “Dry Cutting.” CIRP Annals 46(2):519–26.
Kordonowy, David N. (David Nathaniel) 1981-. 2002. “A Power Assessment of Machining Tools.” Massachusetts Institute of Technology.
Lee, B. Y. and Y. S. Tarng. 1999. “Application of the Discrete Wavelet Transform to the Monitoring of Tool Failure in End Milling Using the Spindle Motor Current.” International Journal of Advanced Manufacturing Technology. 15(4), 238-243.
Lee J-Y, Kim M-S, Yoon H-S, Lee J-C, Moon J-S, Ahn S. H. 2013. “Control of Cutting Parameters Using Relative Vibration of Milling Tool to Workpiece for Chatter Prediction International Symposium on Green Manufacturing and Application (ISGMA 2013).”
Lee, W. Y., K. W. Kim, and H. C. Sin. 2002. “Cutting Conditions for Finish Turning Process Aiming: The Use of Dry Cutting.” International Journal of Machine Tools and Manufacture. 42(8), 899-904.
Li, Congbo, Ying Tang, Longguo Cui, and Pengyu Li. 2015. “A Quantitative Approach to Analyze Carbon Emissions of CNC-Based Machining Systems.” Journal of Intelligent Manufacturing. 26(5), 911-922.
Li, Lingling, Congbo Li, Ying Tang, and Qian Yi. 2017. “Influence Factors and Operational Strategies for Energy Efficiency Improvement of CNC Machining.” Journal of Cleaner Production 161:220–38.
Li, Wen, André Zein, Sami Kara, and Christoph Herrmann. 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.
Liu, Z. Y., M. P. Sealy, Y. B. Guo, and Z. Q. Liu. 2015. “Energy Consumption Characteristics in Finish Hard Milling of Tool Steels.” Procedia Manufacturing 1(December):477–86.
Lv, Jingxiang, Renzhong Tang, Shun Jia, and Ying Liu. 2016. “Experimental Study on Energy Consumption of Computer Numerical Control Machine Tools.” Journal of Cleaner Production. 112, 3864-3874.
Ma, J., X. Ge, S. I. Chang, and S. Lei. 2014. “Assessment of Cutting Energy Consumption and Energy Efficiency in Machining of 4140 Steel.” International Journal of Advanced Manufacturing Technology. 74(9-12), 1701-1708.
Mashood Khan, Aqib, He Ning, Li Liang, and Muhammad Jamil. 2018. “Comment to Paper Entitled ‘Experimental Investigation of Machinability Characteristics and Multiresponse Optimization of End Milling in Aluminium Composites Using RSM Based Grey Relational Analysis’ Measurement 105 (2017) 78–86.” Measurement: Journal of the International Measurement Confederation 119(January):175–77.
Mativenga, P. T. and M. F. Rajemi. 2011. “Calculation of Optimum Cutting Parameters Based on Minimum Energy Footprint.” CIRP Annals - Manufacturing Technology 60(1):149–52.
Meng, Longhui, Aqib Mashood Khan, Hao Zhang, Chenggang Fang, and Ning He. 2020. “Research on Surface Residual Stresses Generated by Milling Ti6Al4V Alloy under Different Pre-Stresses.” International Journal of Advanced Manufacturing Technology. 1-12.
Mia, Mozammel, Munish Kumar Gupta, Jose Adolfo Lozano, Diego Carou, Danil Yu Pimenov, Grzegorz Królczyk, Aqib Mashood Khan, and Nikhil Ranjan Dhar. 2019. “Multi-Objective Optimization and Life Cycle Assessment of Eco-Friendly Cryogenic N2 Assisted Turning of Ti-6Al-4V.” Journal of Cleaner Production. 210, 121-133.
Mia, Mozammel, Munish Kumar Gupta, Catalin Iulian Pruncu, Binayak Sen, Aqib Mashood Khan, Muhammad Jamil, Shafiul Faraz, Fahim Asef, G. M. Shah Imran, and M. Azizur Rahman. 2020. “Six Sigma Optimization of Multiple Machining Characteristics in Hard Turning under Dry, Flood, MQL and Solid Lubrication.” Journal of Production Systems and Manufacturing Science. 1(1), 6-6.
Mori, M., M. Fujishima, Y. Inamasu, and Y. Oda. 2011. “A Study on Energy Efficiency Improvement for Machine Tools.” CIRP Annals - Manufacturing Technology. 60(1), 145-148.
Musfirah, A. H., J. A. Ghani, and C. H. Ch. Haron. 2017. “Tool Wear and Surface Integrity of Inconel 718 in Dry and Cryogenic Coolant at High Cutting Speed.” Wear. 376, 125-133.
Mushtaq, Ray Tahir, Yanen Wang, Mudassar Rehman, Aqib Mashood Khan, and Mozammel Mia. 2020. “State-Of-The-Art and Trends in CO2 Laser Cutting of Polymeric Materials—A Review.” Materials 13(17):3839.
NARITA, Hirohisa, Hiroshi KAWAMURA, Takashi NORIHISA, Lian-yi CHEN, Hideo FUJIMOTO, and Takao HASEBE. 2006. “Development of Prediction System for Environmental Burden for Machine Tool Operation.” JSME International Journal Series C.
Narita, Hirohisa, Hiroshi Kawamura, Takashi Norihisa, Lian Yi Chen, Hideo Fujimoto, and Takao Hasebe. 2007. “Development of Prediction System for Environmental Burden for Machine Tool Operation (1st Report, Proposal of Calculation Method for Environmental Burden).” JSME International Journal, Series C: Mechanical Systems, Machine Elements and Manufacturing. 49(4), 1188-1195.
Neugebauer, R., A. Schubert, B. Reichmann, and M. Dix. 2011. “Influence Exerted by Tool Properties on the Energy Efficiency during Drilling and Turning Operations.” CIRP Journal of Manufacturing Science and Technology. 4(2), 161-169.
Newman, S. T., A. Nassehi, R. Imani-Asrai, and V. Dhokia. 2012. “Energy Efficient Process Planning for CNC Machining.” CIRP Journal of Manufacturing Science and Technology 5(2):127–36.
Oda, Y., M. Mori, K. Ogawa, S. Nishida, M. Fujishima, and T. Kawamura. 2012. “Study of Optimal Cutting Condition for Energy Efficiency Improvement in Ball End Milling with Tool-Workpiece Inclination.” CIRP Annals - Manufacturing Technology. 1 (2012): 119-122.
Park, Cheol Woo, Kye Si Kwon, Wook Bae Kim, Byung Kwon Min, Sung Jun Park, In Ha Sung, Young Sik Yoon, Kyung Soo Lee, Ong Hang Lee, and Jongwon Seok. 2009. “Energy Consumption Reduction Technology in Manufacturing - A Selective Review of Policies, Standards, and Research.” International Journal of Precision Engineering and Manufacturing. 10(5), 151-173.
Peng, Tao and Xun Xu. 2012. “The State of the Art in Energy Consumption Model-the Key to Sustainable Machining.” in Applied Mechanics and Materials.
Peng, Tao and Xun Xu. 2014. “Energy-Efficient Machining Systems: A Critical Review.” International Journal of Advanced Manufacturing Technology. 72(9-12), 1389-1406.
Qian, Ning, Yucan Fu, Jiajia Chen, Aqib Mashood Khan, and Jiuhua Xu. 2020. “Axial Rotating Heat-Pipe Grinding Wheel for Eco–Benign Machining: A Novel Method for Dry Profile-Grinding of Ti–6Al–4V Alloy.” Journal of Manufacturing Processes. 56, 216-227.
Quintana, G., J. Ciurana, and J. Ribatallada. 2011. “Modelling Power Consumption in Ball-End Milling Operations.” Materials and Manufacturing Processes. 26(5), 746-756.
Rajemi, M. F., P. T. Mativenga, and A. Aramcharoen. 2010. “Sustainable Machining: Selection of Optimum Turning Conditions Based on Minimum Energy Considerations.” Journal of Cleaner Production 18(10–11):1059–65.
Reddy, Narala Suresh Kumar, Mohammed Nouari, and Minyang Yang. 2010. “Development of Electrostatic Solid Lubrication System for Improvement in Machining Process Performance.” International Journal of Machine Tools and Manufacture. 50(9), 789-797.
Said, Zafar, Munish Gupta, Hussien Hegab, Neeti Arora, Aqib Mashood Khan, Muhammad Jamil, and Evangelos Bellos. 2019. “A Comprehensive Review on Minimum Quantity Lubrication (MQL) in Machining Processes Using Nano-Cutting Fluids.” The International Journal of Advanced Manufacturing Technology 105(5–6):2057–86.
Salman Jafar, Aqib Mashood Khan, Muhammad Jamil, Xiaoyuan Chen, Qazi Salman. n.d. “Module Optimization and Decision Model for End-of-Life of Machine Tools.” (1),(1-7).
Salonitis, Konstantinos and Peter Ball. 2013. “Energy Efficient Manufacturing from Machine Tools to Manufacturing Systems.” in Procedia CIRP. 7, 634-639.
Sarikaya, Murat and Abdulkadir Güllü. 2015. “Multi-Response Optimization of Minimum Quantity Lubrication Parameters Using Taguchi-Based Grey Relational Analysis in Turning of Difficult-to-Cut Alloy Haynes 25.” Journal of Cleaner Production 91:347–57.
Shan, Zhongde, Shaoyan Qin, Qian Liu, and Feng Liu. 2012. “Key Manufacturing Technology & Equipment for Energy Saving and Emissions Reduction in Mechanical Equipment Industry.” International Journal of Precision Engineering and Manufacturing. 13(7), 1095-1100.
Shao, Guodong, Deogratias Kibira, and Kevin Lyons. 2010. “A Virtual Machining Model for Sustainability Analysis.” in Proceedings of the ASME Design Engineering Technical Conference. (Vol. 44113, pp. 875-883).
Shao, H., H. L. Wang, and X. M. Zhao. 2004. “A Cutting Power Model for Tool Wear Monitoring in Milling.” International Journal of Machine Tools and Manufacture. 44(14), 1503-1509.
Sharma, Vishal S., Manu Dogra, and N. M. Suri. 2009. “Cooling Techniques for Improved Productivity in Turning.” International Journal of Machine Tools and Manufacture 49(6):435–53.
Shin, Seung Jun, Jungyub Woo, and Sudarsan Rachuri. 2017. “Energy Efficiency of Milling Machining: Component Modeling and Online Optimization of Cutting Parameters.” Journal of Cleaner Production 161:12–29.
Singh, Gur Raj, Vishal S. Sharma, and Munish Kumar Gupta. 2018. “Sustainable Drilling of Aluminium 6061-T6 Alloy by Using Nano-Fluids and Ranque-Hilsch Vortex Tube Assisted by MQL: An Optimisation Approach.” International Journal of Machining and Machinability of Materials. 20(3), 252-273.
Singh, Gurraj, Munish Kumar Gupta, Hussein Hegab, Aqib Mashood Khan, Qinghua Song, Zhanqiang Liu, Mozammel Mia, Muhammed Jamil, Vishal S. Sharma, Murat Sarikaya, and Catalin Iulian Pruncu. 2020. “Progress for Sustainability in the Mist Assisted Cooling Techniques: A Critical Review.” International Journal of Advanced Manufacturing Technology. 1-32.
Su, Yu. 2016. “Investigation into the Role of Cooling/Lubrication Effect of Cryogenic Minimum Quantity Lubrication in Machining of AISI H13 Steel by Three-Dimensional Finite Element Method.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 230(6), 1003-1016.
Sutherland, J. W., J. L. Rivera, K. L. Brown, M. Law, M. J. Hutchins, T. L. Jenkins, and K. R. Haapala. 2008. “Challenges for the Manufacturing Enterprise to Achieve Sustainable Development.” in Manufacturing Systems and Technologies for the New Frontier. 15-18.
Tampus. 2013. “Energy-Saving Tactics for Machine Tools.” 2, 231-245
Thakur, A. and S. Gangopadhyay. 2016. “State-of-the-Art in Surface Integrity in Machining of Nickel-Based Super Alloys.” International Journal of Machine Tools and Manufacture. 100, 25-54.
Trianni, Andrea, Enrico Cagno, and Alessio De Donatis. 2014. “A Framework to Characterize Energy Efficiency Measures.” Applied Energy. 118, 207-220.
Ul Haq, Muhammad, Aqib Khan, Le Gong, Tao Xu, Longhui Meng, and Salman Hussain. 2018. “A Comparative Study of Face Milling of D2 Steel Using Al2O3 Based Nanofluid Minimum Quantity Lubrication and Minimum Quantity Lubrication.” Advances in Science and Technology Research Journal 12(1):99–105.
Velchev, Stefan, Ivan Kolev, Krasimir Ivanov, and Simeon Gechevski. 2014. “Empirical Models for Specific Energy Consumption and Optimization of Cutting Parameters for Minimizing Energy Consumption during Turning.” Journal of Cleaner Production 80:139–49.
Vijayaraghavan, A. and D. Dornfeld. 2010. “Automated Energy Monitoring of Machine Tools.” CIRP Annals - Manufacturing Technology. 59(1), 21-24.
Wang, Qiang and Yong Chen. 2010. “Energy Saving and Emission Reduction Revolutionizing China’s Environmental Protection.” Renewable and Sustainable Energy Reviews. 14(1), 535-539.
Wang, Qiulian, Fei Liu, and Congbo Li. 2013. “An Integrated Method for Assessing the Energy Efficiency of Machining Workshop.” Journal of Cleaner Production. 52, 122-133.
Weinert, K., I. Inasaki, J. W. Sutherland, and T. Wakabayashi. 2004. “Dry Machining and Minimum Quantity Lubrication.” CIRP Annals - Manufacturing Technology. 53(2), 511-537.
Xia, Hongjun, Guolong Zhao, Maoshun Hu, Liang Li, Aqib Mashood Khan, and Ning He. 2020. “Investigation on Laser-Induced Oxidation Assisted Micro-Milling of Inconel 718.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 234(8), 1102-1112.
Yan, Jihong and Lin Li. 2013a. “Multi-Objective Optimization of Milling Parameters-the Trade-Offs between Energy, Production Rate and Cutting Quality.” Journal of Cleaner Production 52:462–71.
Yoon, Hae Sung, Binayak Bhandari, Jong Seol Moon, Chung Soo Kim, Gyu Bong Lee, Kwang Wook Park, Chul Ki Song, and Sung Hoon Ahn. 2012. “Energy Analysis of Micro-Drilling Process Used to Manufacture Printed Circuit Boards.” in Leveraging Technology for a Sustainable World - Proceedings of the 19th CIRP Conference on Life Cycle Engineering.
Yoon, Hae Sung, Eun Seob Kim, Min Soo Kim, Jang Yeob Lee, Gyu Bong Lee, and Sung Hoon Ahn. 2015. “Towards Greener Machine Tools - A Review on Energy Saving Strategies and Technologies.” Renewable and Sustainable Energy Reviews. 48, 870-891.
Yoon, Hae Sung, Jong Seol Moon, Minh Quan Pham, Gyu Bong Lee, and Sung Hoon Ahn. 2013. “Control of Machining Parameters for Energy and Cost Savings in Micro-Scale Drilling of PCBs.” Journal of Cleaner Production. 54, 41-48.
Yuan, S. M., L. T. Yan, W. D. Liu, and Q. Liu. 2011. “Effects of Cooling Air Temperature on Cryogenic Machining of Ti-6Al-4V Alloy.” Journal of Materials Processing Technology 211(3):356–62.
Zein, Andr, Wen Li, Christoph Herrmann, and Sami Kara. 2011. “Energy Efficiency Measures for the Design and Operation of Machine Tools: An Axiomatic Approach.” in Glocalized Solutions for Sustainability in Manufacturing - Proceedings of the 18th CIRP International Conference on Life Cycle Engineering. 22-34.
Zhang, Fang and Keman Huang. 2017. “The Role of Government in Industrial Energy Conservation in China: Lessons from the Iron and Steel Industry.” Energy for Sustainable Development 39:101–14.
Zhang, Lin, Longfei Zhou, Lei Ren, and Yuanjun Laili. 2019. “Modeling and Simulation in Intelligent Manufacturing.” Computers in Industry. 112, 103123.
Zhao, G. Y., Z. Y. Liu, Y. He, H. J. Cao, and Y. B. Guo. 2017. “Energy Consumption in Machining: Classification, Prediction, and Reduction Strategy.” Energy. 133, 142-157.
Zhao, Guoyong, Chunhong Hou, Jianfang Qiao, and Xiang Cheng. 2016. “Energy Consumption Characteristics Evaluation Method in Turning.” Advances in Mechanical Engineering. 8(11), 168-178.
Zhong, Qianqian, Renzhong Tang, Jingxiang Lv, Shun Jia, and Mingzhou Jin. 2016. “Evaluation on Models of Calculating Energy Consumption in Metal Cutting Processes: A Case of External Turning Process.” International Journal of Advanced Manufacturing Technology 82(9–12):2087–99.
Zhou, Lirong, Jianfeng Li, Fangyi Li, Qiang Meng, Jing Li, and Xingshuo Xu. 2016. “Energy Consumption Model and Energy Efficiency of Machine Tools: A Comprehensive Literature Review.” Journal of Cleaner Production 112:3721–34.

Published

2020-09-24 — Updated on 2020-10-27

Versions

How to Cite

Khan, A. M. ., He, N. ., Jamil, M. ., & Raza, S. M. . (2020). Energy characterization and energy-saving strategies in sustainable machining processes: A state-of-the-art review. Journal of Production Systems and Manufacturing Science, 2(1), 26-49. Retrieved from http://imperialopen.com/index.php/JPSMS/article/view/47 (Original work published September 24, 2020)

Issue

Section

Review Articles