State-of-the-art review of energy consumption in machining operations: Challenges and trends

Conventional machining operations such as turning, drilling, milling, grinding, etc. consume significant amounts of energy which can vary depending on many factors. Such factors include the levels of cutting parameters, the use of coolants and their types (i.e., water- or oil-based coolants, cryogenics, cold air), types of material being machined and its properties, and size and geometrical complexity, among others. Therefore, it is very important to determine effective ways to minimize energy consumption during conventional machining operations. This article provides an overview of energy consumption and improvement in energy efficiency in various conventional machining processes by an embodied energy analysis from primary and secondary consumption sources. The energy consumption in conventional machining processes can be reduced by better control of the primary and secondary consumption sources and by using more efficient machining-assisting technologies and equipment, or through the continuous monitoring and control of energy usage at different stages of the machining process including that consumed in infrastructure and other less directly related factors. The article also presents challenges and future trends regarding energy consumption and control using available and emerging techniques in the manufacturing industry.