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Review of Literature

2.1 Introduction
In the present manufacturing scenario of increasing demand for energy and global
energy crisis, development of green machining strategies to reduce energy consumption is
of utmost importance. There is an increasing pressure for every manufacturer to go ‘Green’
during manufacturing. Green manufacturing is a modern technique where emphasis is given
on reducing energy and resource consumption, avo id wastage, and reduce harmful
environmental effects during machining without sacrificing on productivity, quality,
profitability and efficient performance. It also encompasses the issues of reducing noise,
health hazards and waste emissions during machining and enhancing security. According to
US Environmental Protection Agency, green engineering is the design, commercialization,
and use of processes and products, which are feasible and economical while minimizing (i)
generation of pollution at the source and (ii) risk to human health and the environment. Due
to the government regulations and growing consumer preference for green products,
manufacturers have begun to explore means of reducing both the quantity and impact of
effluents with improved ways. Green manufacturing holds potential economic benefits
including long term cost savings, waste reductions and process efficiency improvements and
is the key to address the increasing concern about the environment. Green machining is an
approach to solve the environmental pollution problem in manufacturing industry by
controlling pollution at the source and reducing resource consumption. It has become an
essential and fast developing research area in manufacturing. The objective of green
machining is to optimize the raw material consumption, secondary material (e.g. coolant)
consumption, energy consumption and environmental impacts to make the manufacturing
processes eco-friendly. In short, it should have less environmental effects by maximum
utilization of resources. It is a supportive method to make machining process eco-friendly.
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 Literature Review

Researchers are trying to innovate green methods and technology for machining. The
following Section presents the research efforts found in the literature on green
manufacturing.

2.2 Literature on Green Manufacturing

Green manufacturing or green machining is a relatively recent approach in
manufacturing. Although many researchers are working on green machining, the literature
on green machining is not abundant. Literature review reveals that there has been some
awareness for green machining in the last decade. Of late, there has been increasing amount
of research efforts on energy efficiency and environmental effects of machining. Some
important literatures on green machining are discussed hereunder.
It is an established fact that material removal rate (MRR) plays a dominant role in
cutting energy and power requirement during machining. A number of theoretical and
experimental research works are going on to study the effect of process parameters and
MRR on energy and power demand during machining (Dahmus and Gutowski, 2004;
Rodrigues and Coelho, 2007; Neugebaueret al., 2012). In most of these approaches, high
speed machining is preferred for reducing energy.
Dahmus and Gutowski (2004) analyzed the material removal process in four
different milling machines of various levels of automation along with environmental impact
of waste material and cutting fluid. The authors presented the analysis with the help of
energy breakdown at various levels of automation. With increase in degree of automation,
energy consumed by auxiliary equipment goes on reducing even though percentage of
machine hours spent on part positioning is a source of constant power consumption. They
found that the energy requirement of actual material removal is much less compared to the
total energy requirement. For general estimate of energy for machining, the energy per unit
of material removed should be calculated. Moreover, 10—60 % of the raw material is
considered as scrap which implies wastage of raw material. The authors are of the view that
high speed machining should be adopted for reducing energy.
Rodrigues and Coelho (2007) carried out an experimental study on specific c utting
energy as a function of cutting speed and tool cutting edge geometry. They found that
reduction in specific cutting energy is more for high speed cutting than conventional speed
of cutting for the same change in tool cutting edge geometry.

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 Literature Review

Neugebauer et al. (2012) mainly focused on the study of high speed machining
(HSM) and high performance cutting (HPC) and their effects on cutting energy and cutting
time with the variations of MRR, surface quality, tool life, cutting force and power. HSM
has positive effect on tool and machine by reducing the effect of cutting forces and thus
power and energy. The authors found that cutting force decreases with increase in cutting
velocity and reduction in cutting force dominates the increase in power consumption. In
HPC, with increase in feed rate and depth of cut, cutting force increases which ultimately
increases power consumption. But the authors gave priority to higher feed than depth of cut
since reduction of specific cutting force is more significant in case of higher feed. They
presented some examples on the influence of process parameters on energy and resource
efficiency in various machining processes like turning, milling, drilling, and grinding.
Influence of process parameters and machine tool design on energy consumption
during machining has been the focus of extensive research by Diaz et al. (2009, 2010, and
2011). The authors conducted several experimental studies using different milling machines
and emphasised on developing green machine tools to reduce energy demand.
Diaz et al. (2009) studied the influence of process parameters like feed per tooth,
spindle speed and feed rate on energy per unit manufactured using Mori Seiki
NV1500DCG, a micromachining centre where power consumption is measured with power
meter. Results showed that though energy per unit manufactured is reduced with increase in
feed rate, increase in feed per tooth is more effective for tool wear reduction and improving
surface quality. Energy per unit manufactured is decreased dramatically because of the use
of high speed machining against conventional machining. A massive portion of a machine
tool’s total power demand is consumed by cutting power responsible for removal of
material.
Life-cycle energy consumption by machine tool is we ll discussed by Diaz et al.
(2010). Life-cycle energy consumption analysis of milling machines showed that the energy
consumed is affected by several factors such as process parameters, degree of automation,
manufacturing environment, type of raw material, and peripheral equipment. The authors
used two types of machine tools, one of low automation and the other is highly automated.
In addition to life-cycle energy consumption, the authors presented a strategy KERS (kinetic
energy recovery system). KERS recovers energy from cutting process which directly
impacts on overall energy demand of machine tools. A simulation using KERS on Mori
Seiki NV1500DCG results 5—25% reduction of power consumption as compared to

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 Literature Review

simulation without KERS. The authors also presented a Web-based energy estimation tool
to estimate the energy consumption of machine tool.
Diaz et al. (2011) analysed the effect of cutting parameters, viz. feed, depth of cut
and spindle speed thereby material removal rate (MRR) on power consumption. Authors
used a micromachining centre for the experiments. Experimental results showed that though
power consumption increases with increase in MRR, decrease in machining time ultimately
reduces the energy consumption.
Green machining concept is also getting prime importance in process planning for
machining. Process planning is a crucial step for machining a component. Several attempts
to develop green process planning are found in the literature (Sheng and Srinivasan,1995;
Yeo and New, 1999; Krishnan and Sheng, 2000; Durham, 2002; Liu Fei et al., 2005; Tsai-
chi kuo et al., 2005; Yan et al., 2007; Jadhav and Bilgi, 2008; Jianget al. 2008; Park et al.,
2009).
Sheng and Srinivasan (1995) presented a system prioritization matrix using the
Analytic hierarchy process (AHP). The objective of this planning scheme are to select an
optimal process path and parameters from a set of alternative paths which best reflect t he
manufacturing priorities between the environment, production rate and quality factors. By
using analytical modelling, good estimates can be developed for cases where no past data is
available.
Yeo and New (1999) presented a methodology for the multi-objective analysis of the
electric discharge machining (EDM) processes. A utility function was employed to
determine the utility levels of various dielectrics by integrating the factors involving time,
energy and weighted mass.
Krishnan and Sheng (2000) presented an automatic process planning agent for CNC
machining for minimal environmental impact. The process planning system can accept web-
based designs and offers feedback to the designer over the Internet.
Durham (2002) presented a net-shape processing method from total materials cycle
perspective. Environmental management of the total materials cycle provides tools to
evaluate the effect of changes in processing or materials on a global basis, where materials
use and reuse, component remanufacture, and materials recycling can be considered and the
overall costs and impacts are assessed.
Liu Fei et al. (2005) presented a series of investigation and practices on green
manufacturing. They worked on optimizing system for raw materials cutting, energy-saving

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 Literature Review

in machining, the design of efficient dry hobbing machine tools, multi-objective decision-
making model for green manufacturing, etc.
Tsai-chi kuo et al. (2005) presented an innovative method, green fuzzy design
analysis (GFDA), which involves simple and efficient procedures to evaluate product design
alternatives based on environmental consideration using fuzzy logic. The hierarchical
structure of environmentally conscious design indices was constructed using the analytical
hierarchy process (AHP) which includes five aspects: energy, recycling, toxicity, cost and
material. After weighting factors for the environmental attributes are determined, the most
desirable design alternative can be selected based on the Fuzzy multi- attribute decision
making (FMADM) technique.
Yan et al. (2007) presented a process planning support system for green
manufacturing (GMPPSS) to deal with the problems in optimization of environment-
favourable process planning. The objective of the GMPPSS is to evaluate the green
attributes of the process planning considering raw material consumption, secondary material
consumption, energy consumption and environmental impacts of the manufacturing process.
Jadav and Bilgi (2008) presented a process planning system for green manufacturing
to optimize the raw material consumption, secondary material consumption, energy
consumption and environmental impacts of process planning with support of green process
database which makes the manufacturing processes friendlier.
Jiang et al. (2008) presented a process database support system for green
manufacturing with Browser / Server three level structures on the basis of web which has
the function of distributed processing and storage of the data. A process database support
system of green manufacturing process is developed. Process database support system is a
web-based technology which can also be called as a reservoir of digital information.
Information includes green database and knowledge database.
Park et al. (2009) thoroughly investigated energy-saving technologies and related
policies, particularly in the manufacturing industry, by focusing on the energy structure in
manufacturing, energy policies and management standards in several major countries,
energy-saving technologies both in the manufacturing and non- manufacturing sectors, along
with the effects eco-friendly green manufacturing technologies have on economies and the
environment.

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 Literature Review

2.3 Summary of Literature Review

From the literature review on green machining, it is evident that green machining is
a very important issue in today’s manufacturing scenario. Green machining methods can
lead to less energy consumption and protect the environment. Although various researchers
are working on developing green machining technologies, the efforts are not enough to meet
the global energy crisis and environmental threats. The worldwide demand for energy has
increased manifold in the last two decades. This growing demand for energy involves all
spheres of human civilization thus warrants the need of immediate attention Presently,
global energy crisis is a serious issue of concern and development of green machining
strategies to reduce energy consumption is of utmost importance.

2.4 Specific Objective of the Present Work

Based on the literature review and drawbacks of the conventional machining
methods, it is decided to perform an experimental study on green machining.
In the present work, the objective is to perform an experimental study to find the
effect of process parameters; viz. feed rate, depth of cut, and cutting velocity and the effect
of material removal rate (MRR) on specific energy consumption and cutting power demand
in machining of rectangular slots using end milling operation. The MRR is to be increased
by increasing the feed rate and depth of cut.

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