Energy and CO₂ emissions modeling for unconventional machining industry considering processing characteristics

Area of Science:

• Manufacturing Engineering
• Sustainable Manufacturing
• Industrial Ecology

Background:

• Wire Electrical Discharge Machining (WEDM) is crucial in modern manufacturing.
• Optimizing WEDM efficiency and resource use is key for sustainable development.
• Accurate energy and CO2 emission modeling is needed for WEDM process improvement.

Purpose of the Study:

• To develop a predictive model for energy consumption and CO2 emissions in WEDM.
• To analyze the impact of process characteristics on WEDM energy use and emissions.
• To propose new standards for cutting fluid substitution and identify factors influencing energy consumption.

Main Methods:

• Development of a predictive model for WEDM energy consumption and CO2 emissions.
• Incorporation of process characteristics into the predictive model.
• Case study analysis to validate model accuracy and explore influencing factors.

Main Results:

• The predictive model achieved high accuracy: 96.5% for single part processing and over 99% for batch processing.
• Geometric features like corners reduce energy consumption; fewer folding angles decrease energy use.
• Workpiece thickness, electrode wire life, and auxiliary material quality significantly impact energy consumption.

Conclusions:

• The developed model provides accurate predictions of WEDM energy consumption and CO2 emissions.
• Understanding process characteristics is vital for optimizing WEDM sustainability.
• The study offers insights into reducing energy use and environmental impact in WEDM.