Energy consumption modeling of ultra-precision machining and the experimental validation

Enormous precision products are fabricated by precision machining technologies nowadays. Ultra-precision diamond cutting, which is one of the most applied machining ways in ultra-precision machining (UPM), figures the importance of precision manufacturing nowadays. However, the existing energy consumption models currently used for UPM are applied to traditional machining processes, of which the energy component of material removal process only considers the assigned material removal volume in UPM. Nevertheless, the material recovery effect is dominant in material removal processes in UPM, which it significantly reduces the assigned material removal volume. This study therefore proposes a modified energy consumption model for the UPM by adding the material recovery factor. The representative machining technology of UPM, ultra-precision diamond cutting, is used for the case study in this study. The experimental results showed that the accuracy percentage of proposed energy component regarding to material removal process increased to 83.39%. Also, the specific energy consumption obtained by the proposed approach increased up to 11.2 times of that of the traditional approach. This study demonstrates the noteworthiness of the material recovery effect on the energy consumption of UPM, providing a valuable insight for arranging realistic environmental plans with references in precision manufacturing industries.