Development of an empirical model to quantify carbon emissions for machining of cylindrical parts

Abstract

As a result of growing environmental issues and stringent carbon emission (CEM) regulations imposed throughout the globe, low CEM has become one of the essential requirements of manufacturing industries. Low-carbon manufacturing, which aims to reduce carbon intensity and improve process efficiency, has evolved as emerging issue that has encouraged a lot of research into quantifying the CEM of different manufacturing processes. To comply with increasingly stringent CEM regulations and achieve low carbon manufacturing, manufacturing industries require accurate CEM data for their products. In this work, an empirical model is developed to quantify carbon emissions for machining of cylindrical parts. The CEM associated with a cylindrical part machining is decomposed into CEM from electrical energy consumption, material consumption, cutting tool wear, and coolant consumption and from the disposal of machining waste materials. Electrical energy consumption of a machine tool is further decomposed into different energy modules: startup, standby, spindle acceleration, idle, rapid positioning, air-cutting, and cutting for accurate quantification of CEM. Energy consumption models are developed for each module, and are integrated to quantify the total energy consumption of the machine tool. Finally, the developed model is applied on a cylindrical part with three different process plans to validate the developed model for practical implementation in industry. The proposed model can be utilized in the manufacturing industry to quantify carbon emissions based on different process parameters before machining a cylindrical part to achieve low carbon manufacturing process planning and scheduling.