Energy consideration in machining operations - towards explanatory models for optimisation results

Part of: Seliger, Günther (Ed.): Innovative solutions : proceedings / 11th Global Conference on Sustainable Manufacturing, Berlin, Germany, 23rd - 25th September, 2013. - Berlin: Universitätsverlag der TU Berlin, 2013. - ISBN 978-3-7983-2609-5 (online). - http://nbn-resolving.de/urn:nbn:de:kobv:83-opus4-40276. - pp. 153–158.This paper reports the application of a systematic research methodology for uncovering the reasons behind results obtained when energy is considered in machining optimisation. A direct search optimisation method was used as a numerical experimentation rig to investigate the reasoning behind the results obtained in applying Taguchi methods and Genetic algorithm (GA). Representative data was extracted from validated machining science equations and studied using graphical multivariate data analysis. The results showed that over 80% of reduction in energy consumption could be achieved over the recommendations from machining handbooks. It was shown that energy was non-conflicting with the cost and time, but conflicting with quality factors such as surface roughness and technical factors such as power requirement and cutting force. These characteristics of the solutions can provide an explanative motif required for practitioners to trust and use the optimisation results