Experimental characterization of energy consumption in 5-axis milling machine and developing optimization strategy

The optimization of machining processes is of paramount significance because of its pivotal role in modern manufacturing. Efficient machining techniques not only enhance product quality but also reduce costs and environmental impacts. This study focuses on the experimental characterization of energy consumption in a 5-axis milling machine and the simulation of possible solutions to reduce it. The first step is to understand the key drivers of energy consumption which is crucial for enhancing energy management and optimization. This was achieved by developing a mathematical model that uses the most common machining parameters as input using a Response Surface Methodology experimental test plan and an analysis of the contributions of the auxiliary systems to the overall energy consumption. As a second step, the effectiveness of different solutions was simulated considering different application scenario, like the type of operations. Such solutions include the introduction of duty cycle strategies for some auxiliary systems and the optimization of process parameters.