Development of a novel CNC energy consumption model and energy analyzer software: towards energy-efficient tool pathway strategies in CNC machining

Abstract This study proposes energy-saving strategies for CNC machining, to address the significant energy consumption challenges encountered in the manufacturing sector. A novel energy consumption model for three axis CNC milling machines is presented in this study. This energy model computes energy consumption of a CNC machine based on a given numeric code. The model categorizes energy consumption in CNC machining into seven divisions. Each of the seven energy divisions has its own corresponding power state which were analyzed individually in controlled experiments. An energy analyzer software was developed to compute energy consumption in CNC machining, based on numeric codes. The software then selects the most energy efficient tool pathway strategy. By conducting some machining trials, the energy model and software were validated. The greatest percentage deviation of the software predictions from the measured energy consumption was − 1.9%. Nine tool pathway strategies were studied. The energy consumption of the nine tool pathway strategies was examined on two geometries, the rectangular pocket and the circular pocket. Results from the software revealed the pocket-in and the pocket-out tool pathways were the most energy efficient tool pathway strategies for both the rectangular pocket and the circular pocket. With the significant variation of energy consumption observed across the nine tool pathway strategies, the energy savings were up to 67% for rectangular pockets and up to 33% for circular pockets.