Energy efficiency of state-of-the-art grinding processes

In times of unstable market development due to the energy system transformation and legislative measures concerning the reduction of CO2 emissions, the manufacturing industry is increasingly aware of the ecological and economical importance of the factor energy. A considerable share of industrial energy and resource consumption can be attributed to machine tools in general and grinding machines in particular. Grinding is an essential technology used for finishing operations of many precision components, especially such made of hard and brittle materials. This work presents an investigation in the energy consumption related to high-performance grinding processes. Grinding tests were performed using different grinding strategies and abrasives including corundum (Al2O3) and CBN. In order to identify the dynamic process behavior and energy flows, process parameters were varied and electrical power consumption of the CNC grinding machine, its drive system as well as different peripherals such as cooling lubricant pumps were measured. Specific energy consumption was determined as a function of material removal rate and compared to results of milling and turning processes. The key influence factors on grinding energy efficiency and productivity are depicted. Strategies are evaluated to optimize the overall process performance from an energetic point of view.