A novel intelligent reasoning method to estimate the cutting system energy consumption for a sustainable manufacturing

ABSTRACT Facing the increasing rhythm of technological progress we are witnessing with the fast pace of modern life and the growing interest in the environment, machine tools energy estimation has become intrinsic for the manufacturing industries. Basically, during material removal, investigators tend to neglect the cutting forces nonlinearities entailed by the trochoidal trajectories of the cutting edge and the tool run-out despite their effect on the consumed cutting energy. From this perspective, in this research paper, we set forward the Independent Component Analysis (ICA) algorithm as another alternative allowing the estimation of the dynamic cutting forces in the first place, then at a later stage the computation of the estimated cutting energy and power during material removal using the CNC machine tool. Both of the finite element method and the formulation of the equation of motion were applied to validate the estimated cutting forces. The achieved power and energy results were validated through experimental measurements. The obtained experimental results go in good consistency with the numerical ones. Thus, the ICA can be considered as a novel and promising technique in the manufacturing field in terms of the estimation of energy consumption.