Energy oriented multi cutting parameter optimization in face milling

A new model for evaluating the energy consumed by a machine tool for processing a prismatic workpiece was developed. The model takes into account the energy absorbed by different machine components such as the auxiliary systems, the axes, the axes chiller, the tool change system, chip conveyor and the spindle system. The relationships between the power absorption of each considered machine component and the main cutting parameters were adequately modeled. The cutting energy was also taken into consideration. Since the wear of the tool was included in the model, the energy absorbed by the machine during passive phases (e.g. tool changes) was also evaluated. Each machine component model was opportunely configured according to the considered production phase. Some of the parameters of the machine tool energy model were identified through experimental tests performed on a real machining center equipped with linear motors. A multivariable energy optimization was carried out considering the cutting speed, the feed and the radial depth of cut as the main parameters. The energy minimization was performed through exhaustive enumeration methods. Results were properly discussed and analyzed. The optimization analysis was also repeated emulating various machine tool configurations and different production scenarios