Sequencing the features to minimise the non-cutting energy consumption in machining considering the change of spindle rotation speed

•Non-cutting energy consumption is reduced by adjusting the processing sequence.•Power of machine tool during spindle acceleration and deceleration is analysed.•Energy consumed for the change of spindle rotation speed is modelled.•The optimal processing sequence is obtained by Ant Colony Optimisation.•The developed sequencing approach is demonstrated, compared and discussed.

A considerable amount of energy consumed by machine tools is attributable to non-cutting operations, including tool path, tool change, and change of spindle rotation speed. The non-cutting energy consumption of the machine tool (NCE) is affected by the processing sequence of the features of a specific part (PFS) because the plans of non-cutting operations will vary based on the different PFS. This article aims to understand the NCE between processing a specific feature and its pre- or post-feature, especially the energy consumed during the speed change of the spindle rotation. Based on the developed model, a single objective optimisation problem is introduced that minimises the NCE. Then, Ant Colony Optimisation (ACO) is employed to search for the optimal PFS. A case study is developed to validate the effectiveness of the proposed approach. Two parts with 12 and 15 features are processed on a machining centre. The simulation experiment results show that the optimal or near-optimal PFS can be found. Consequently, 8.70% and 30.42% reductions in NCE are achieved for part A and part B, respectively. Further, the performance of ACO for our specific optimisation problem is discussed and validated based on comparisons with other algorithms.