Modelling of specific energy requirements in machining as a function of tool and lubricoolant usage

The attention to the environmental impact analysis of manufacturing processes has been increasing. Energy consumption is one of the main players for material removal processes. Models for estimating the specific energy consumption or for computing the total direct energy requirements have been developed over time. This paper proposes a comprehensive model for the system-level energetic analysis of machining processes, which includes all the activities related to workpiece material production, material removal, tool and cutting fluid production and usage. The application of the model to the turning of a Ti-6Al-4V alloy (under wet, MQL, and dry cutting conditions) is presented and discussed. The results allow identifying the optimum process parameters for energy consumption minimization.