Development of design software for rotational parts based on energy consumption and carbon footprint estimation model

Date

2024-6

Author

Uluer, Muhtar Ural

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This study develops a model to estimate the electrical energy consumption and its environmental impact for a rotational product during manufacturing. Energy consumed for manufacturing processes is investigated under two components: theoretical and auxiliary energy. Theoretical energy is consumed for actual metal removal processes and it is estimated by using the specific cutting energy and the volume of chip removed for each STEP AP224 feature of the design. Auxiliary energy is consumed by the peripheral equipment of a CNC lathe such as coolant system, spindle motor and axis servos. It is estimated by using power requirement of each auxiliary equipment and their utilization time. Power requirement is based on measurements and empirical findings. Time is calculated from the tool path movements and cutting parameters. Estimated manufacturing process energy is converted to carbon emissions by using Carbon Emission Signature (CESTM) method. This method utilizes the fractions of primary energy sources that use fossil fuels and a conversion efficiency factor. These fractions are obtained from Turkish Electricity Transmission Company (TEİAŞ) data. Estimation model is integrated into TurnDesign Eco Edition, a feature modelling software for rotational parts. It estimates energy consumption and carbon footprints of rotational parts in the early design stages, enabling design engineer to make energy aware decisions. Developed model is verified by measuring energy consumptions of 5 sample parts with different geometries and materials. Measurements are done using a Siemens Sentron PAC3200 power meter, installed on Anatool TP 32 CNC lathe at the Department of Mechanical Engineering, METU.

Subject Keywords

Sustainable manufacturing, Energy estimation, Carbon footprint, Energy monitoring on CNC lathe

URI

https://hdl.handle.net/11511/110122

Collections

Graduate School of Natural and Applied Sciences, Thesis