Prioritizing energy-intensive machining operations and gauging the influence of electric parameters: an industrial case study

Increasing the energy efficiency of machining operations can contribute to more sustainable manufacturing. Therefore, there is a necessity to investigate, evaluate, and optimize the energy consumed during machining operations. The research highlights a method employed to prioritize the most energy-intensive machining operation and highlights the significance of electric parameters as predictors in power estimation of machining operations. Multi regression modeling with standardized regression weights was used to identify significant power quality predictors for active power evaluation for machining operations. The absolute error and the relative error both decreased when the active power was measured by the power analyzer for each of the identified machining operations, compared to the standard power equation and that obtained from the modeled regression equations. Furthermore, to determine energy-intensive machining operation, a hybrid decision-making technique based on TOPSIS (a technique for order preference by similarity to ideal solution) and DoM (degree of membership) was utilized. Allocation of weights to energy responses was carried out using three methods, i.e., equal importance, entropy weights, and the AHP (analytical hierarchy process). Results revealed that a drilling process carried out on material ST 52.3 is energy-intensive. This accentuates the significance of electric parameters in the assessment of active power during machining operations.