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This research addresses the environmental impact of machining processes in the industrial sector, emphasizing resource consumption in the form of lubricants, tools, and electrical energy. With a focus on reducing the environmental impact, this study conducts a cutting parameters optimization using screening Life Cycle Assessment results. Despite electricity consumption being substantial, the research highlights the significant role of tool wear and lubricant in specific environmental indicators. In the context of the study, the results show a significant accuracy between the modeling and the experimental results. The optimization of cutting parameters proves to be complex, especially for cutting speed, as the multi-objective nature of environmental analysis methods yields different optima based on various environmental indicators. Given the current focus on the intrinsic comparison of different indicators in the litterature, the proposed method allows for a single-criteria optimization of environmental impact based on the chosen indicator. The challenges in the environmental analysis of manufacturing processes lie in achieving a consensus on a reliable and robust environmental analysis method that facilitates the optimization of their environmental impact.

Blade wear is an essential factor that influence textile cutting quality and precision and it is important to seek an appropriate method to predict the cutting tool conditions. In this study, the vertical force range of the blade are measured to determine the vibrating blade’s abrasive wear during different cutting conditions of superimposed plies of a flexible material “Denim”. The relationship between cutting force against the abrasive wear is studied and identified through the evolution of the roughness and the cutting edge radius, which provides a technical foundations for online monitoring of the blade’s wear conditions and cutting quality. Moreover, this study analyzes the sharpening conditions of three different HSS blades in order to regenerate the suitable tool’s cutting edge. It is shown that with incorporation of the vertical cutting force factor we can predict conveniently the tool wear condition and start the sharpening procedure at the accurate time.

Energy consumption during manufacturing is a key element for the environmental impact assessment in modern industry. In order to optimize and avoid undesirable residual deformations in the final product in an overall manufacturing process, it is necessary to correctly identify the variables that describe the state of the matter. This will allow to recreate the interaction existing between the individual process in the global chain. Numerical simulations results of a chain of combined solicitations, using different hardening rules for the same material, show the importance of this choice when the simulation of successive processes is foreseen.

In the manufacturing process the interaction tool/chip/machine-tool generates cutting forces and also moments (a complete torsor) on the tool in three directions. These moments represent a significant proportion of energy consumed in cutting process. The aim of this paper is a dynamic analysis applied to the mechanical actions (the complete torsor) and the mechanical vibrations to develop a monitoring and diagnosis approach in three-dimensional case. The method used in our research refers to an advanced analysis of mechanical actions to obtain the response of the milling tool during the cutting process and also to identify various defects. An important approach in monitoring process is based on the synchronous envelope (SEA) applied on cutting vibration continuing with the dynamic analysis of the moments. To understand the dynamic phenomena due to the milling process a complex experimental protocol and analysis is designed and realized.