An investigation on the impact of toolpath strategies and machine tool axes configurations on electrical energy demand in mechanical machining

Manufacturing sustainability and minimal environmental impacts of machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool axis configurations on the electrical energy requirements in a milling process. In this work, different toolpath strategies were considered for pocket milling of AISI 1018 steel on two three-axis computer numerical control (CNC) milling machines. It was observed that machining on the y-axis of the conventional CNC milling machine and the x-axis of the high-speed CNC milling machining centre (axes carrying more weights) resulted in higher energy demand when compared with the lighter axis. This study also showed that the electrical energy efficiency of toolpath machining strategy varies from one CNC milling machine to another due to their structural configurations. This work also proposes fundamental measures of selecting the most efficient toolpath strategy for energy consumption management in mechanical machining. This could further raise the integrity of sustainable machining strategies for energy efficiency in the manufacturing industries. The knowledge obtained would aid in improving energy efficiency in mechanical machining and also reduce the environmental impacts.