Energy Demand Reduction in Milling Based on Component and Toolpath Orientations

Machine tool axis motions are the key movements when milling components and hence it is vital to understand how they influence energy demand in manufacturing. In this research, a systematic study of component and toolpath orientation was undertaken for milling operations. The current and voltage demand was monitored and this allowed evaluation of electrical energy demand. The machine tool was run while executing toolpaths in air (air cutting) and then in actual pocket milling of AISI 1018 steel and the component was rotated in the x-y plane of the machine. It was shown that when machining toolpaths were aligned to the lighter axis, this reduced the feed electrical energy demand by 29%, minimised the drive dynamics, and reduced surface roughness by up to 50%. Different toolpaths were tested in machining a pocket. The most energy efficient toolpath strategy had the best surface finish. Thus there are synergies in setting and programming toolpaths allowing simultaneous reduction of energy demand and component surface roughness. The knowledge obtained in this study is vital guidance for process planners.