Establishing a rapid, accurate, and practical energy consumption evaluation model for machine tools is essential to save energy and increase profits in the manufacturing industry. Relationships between spindle rotation speed, cutting parameters, material removal rate, specific energy consumption, cutting power, and material removal power were experimentally analyzed, and the limitation and the limitation and differences between several machine tools’ cutting power evaluation models were discussed. Cutting parameters or material removal rate were regarded as independent variable in those models. By comparing the models’ fitting and predicted results, it draw a conclusion that the model treating cutting parameters as independent variable had greater accuracy but depends on a large quantity of experimental data. The model treating material removal rate as independent variable can also obtain a good fit and reduce the number of necessary experiments. Therefore, it is a rapid method to estimate the cutting energy consumption of machine tools for the latter model. In addition, the paper puts forward an improved cutting power model, which considers the influence of the spindle rotation speed on the material removal power during the milling process. The proposed model can predict a milling machine’s cutting power more accurately.
Financed by the National Centre for Research and Development under grant No. SP/I/1/77065/10 by the strategic scientific research and experimental development program:
SYNAT - “Interdisciplinary System for Interactive Scientific and Scientific-Technical Information”.