Optimizing Milling Energy Efficiency with a Hybrid PIRF–MLP Model and Novel Spindle Braking System

The increasing demand for energy efficiency in manufacturing has driven the need for advanced modeling techniques to optimize power consumption in machining processes. This study presents a novel approach to modeling power consumption in milling processes using machine learning, leveraging a custom-designed braking device integrated into the milling machine’s main spindle to measure friction forces with high precision. A comprehensive dataset of observations, including parameters such as speed, force, intensity, apparent power, active power, and power factor, was collected under loaded conditions. Nine machine learning models—Linear Regression, Random Forest, Support Vector Regression, Polynomial Regression, Multi-Layer Perceptron with 2 and 3 layers, K-Nearest Neighbors, Bagging, and a hybrid Probabilistic Random Forest—Multi-Layer Perceptron (PIRF–MLP)—were evaluated using 5-fold cross-validation to ensure robust performance assessment. The PIRF–MLP model achieved the highest performance, demonstrating superior accuracy in predicting utile power. The feature importance analysis revealed that force and speed significantly influence power consumption. The proposed methodology, validated on a milling machine, offers a scalable solution for real-time energy monitoring and optimization in machining, contributing to sustainable manufacturing practices. Future work will focus on expanding the dataset and testing the models across diverse machining conditions to enhance generalizability.