Machine-Specific Energy Estimation Using the Unit Process Life Cycle Inventory (UPLCI) Model

Abstract

This paper discusses a method for machine-specific energy estimation in milling processes using the unit process life cycle inventory (UPLCI) model. To this end, we develop a standard methodology for constructing an adjusted UPLCI model that includes adjustment factors for uncertainties in machine tool specifications and the specific cutting energy of a workpiece material. The adjustment factors are calculated through experimental measurement of energy consumption for a standard test part on a specific machine tool. To validate the adjusted UPLCI model, we conducted a case study which experimentally measured the energy consumption for machining three parts made of Aluminum 6082 on a Chevalier QP2040-L three-axis vertical milling machine. Results show that the UPLCI model consistently overestimated the total energy consumption for machining the three parts and had significant estimation errors (314%, 499%, 286%). The largest sources of error in the UPLCI model were from overestimating the idle and basic power consumption of the machine tool. The adjusted UPLCI model significantly reduced the estimation errors for the same tests (27%, 0.3%, 36%).