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Procedia Procedia
CIRP 00 CIRP
(2017)105
000–000
(2022) 192–197
www.elsevier.com/locate/procedia

29th CIRP Life Cycle Engineering Conference

29th CIRP Life Cycle Engineering Conference
Modelling of spindle energy consumption in CNC milling
Modelling28th
ofCIRP
spindle
Designenergy consumption
Conference, inFrance
May 2018, Nantes, CNC milling
Shrikant Shankarrao Pawar, Tufan Chandra Bera*, Kuldip Singh Sangwan
A new methodology
Shrikant Shankarrao toDepartment,
Mechanical Engineering analyze
Pawar, Tufan the functional
Birla Institute
Chandra Bera*, and Kuldip
of Technology and Science, physical
Pilani, architecture
Singh Sangwan
Rajasthan 333031, India. of
existing products for an assembly oriented product family identification
Mechanical Engineering Department, Birla Institute of Technology and Science, Pilani, Rajasthan 333031, India.

* * Corresponding author. Tel.: +91-1596-255874; fax: +91-1596-244183. E-mail address: tcbera@pilani.bits-pilani.ac.in

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* * Corresponding author. Tel.: +91-1596-255874; fax: +91-1596-244183. E-mail address: tcbera@pilani.bits-pilani.ac.in

École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
* Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
In manufacturing industries, machine tools are frequently used and required a lot of energy to work. Spindle acceleration is a common process
when machine tools
In manufacturing are in use.
industries, It generates
machine tools aare
high-energy
frequentlyintensive
used andpowerrequiredpeak. The
a lot oftotal
energyenergy consumption
to work. of machine tools
Spindle acceleration in the machining
is a common process
process
when is strongly
machine toolsaffected by It
are in use. these high-power
generates peaks ofintensive
a high-energy short duration.
power Many researchers
peak. The haveconsumption
total energy overlooked the energy consumption
of machine of spindle
tools in the machining
acceleration
process
Abstract resulting
is strongly into inaccuracies
affected in the prediction
by these high-power peaks ofofshort
overall energyMany
duration. consumption
researchersof machine tools. Therefore,
have overlooked the energytheconsumption
present studyof aims to
spindle
develop a model
acceleration to predict
resulting the spindle acceleration
into inaccuracies energyofconsumption
in the prediction overall energy of consumption
computer numerical control
of machine (CNC)
tools. millingthe
Therefore, machines.
present The
studyproposed
aims to
Inmodel
develop
today’sisabusiness
based
modelon the principle
toenvironment,
predict of spindle
the spindle
the motor control
acceleration
trend towards energy
more and includes
varietythe
consumption
product of computation
andcomputer of is
numerical
customization moment
control
unbroken.of (CNC)
inertia ofthis
thedevelopment,
Due tomilling spindle drive
machines. Thesystem.
the need To
proposed
of
validate
model
agile andisthe effectiveness
based
reconfigurable of the proposed
on the principle
production spindlemodel,
of systems motor machining
emergedcontrol
to copeandexperiments
includes
with the
various are carried and
computation
products out on
of amoment
CNC
product milling machine.
of inertia
families. To of theWithout
design spindle
and performing time-
drive production
optimize system. To
consuming
validateasthe
systems experiments,
effectiveness
well as to choose the proposed
of the proposed
optimal models
productcanmatches,
model, be utilized
machining to estimate
experiments
product the
analysis power,
carried time,
aremethods out
areonand energy
a CNC
needed. consumption
milling
Indeed, machine.
most ofWithout
of the spindle
known acceleration.
performing
methods aim The
time-
to
proposed
consuming
analyze model
a product helps
or onetoproduct
experiments, determine
the proposed total
family onenergy
models consumption
can be utilized
the physical during machining
to estimate
level. Different process
the power,
product correctly.
time,
families, and energy
however, may consumption
differ largelyof in spindle
terms ofacceleration.
the number andThe
proposed
nature model helps This
of components. to determine total energy
fact impedes consumption
an efficient comparisonduringandmachining
choice ofprocess correctly.
appropriate product family combinations for the production
© 2022
system. A The
new Authors. Published
methodology is by ELSEVIER
proposed to analyze B.V.
existing products in view of their functional and physical architecture. The aim is to cluster
© 2022 The Authors. Published by Elsevier B.V.
This
©
these
This is an
2022 anThe
products
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open access
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access article under
Published theELSEVIER
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product
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for (https://creativecommons.org/licenses/by-nc-nd/4.0)
the (https://creativecommons.org/licenses/by-nc-nd/4.0)
optimization of existing assembly lines and the creation of future reconfigurable
Peer-review
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assembly
Peer-review under
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open
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Based article
on Datum
responsibility ofofthe
under the
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Functional
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a Peer-review under responsibility
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the scientific committee
a hybrid of the and
functional 29thphysical
CIRP Life Cycle Engineering
architecture Conference
graph (HyFPAG) is the output which depicts the
Milling; product
Keywords:between
similarity Spindle energy;
familiesIdeal
bypower; Energydesign
providing saving support to both, production system planners and product designers. An illustrative
Keywords:
example of aMilling; Spindleisenergy;
nail-clipper used toIdeal power;
explain theEnergy savingmethodology. An industrial case study on two product families of steering columns of
proposed
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
1. Introduction
Peer-review under responsibility of the scientific committee of the 28th CIRP of Design
electrical energy consumption
Conference 2018. and concerned air pollution is
1. Introduction the prime goal
of electrical to industrial
energy consumption sectors
andfor sustainability.
concerned In order
air pollution is
Manufacturing
Keywords: industries
Assembly; Design consume
method; Family a large
identification amount of to diminish
the prime goaloverall global
to industrial energy
sectors demand, the Inenergy
for sustainability. order
electrical energy and
Manufacturing producesconsume
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amountThe of consumption
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The improvement of
concentration
excessive emission of carbonofdioxide in atmosphere
greenhouse gases has grown 35%
especially the energy efficiency
widely used and assessment
in manufacturing of energy
industries. The demand
improvement through of
1.since
Introduction
the industrial
concentration of carbonrevolution.
dioxideThe emission ofhas
in atmosphere carbongrown 35% ofdeclination
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energy range
of power
efficiency andand characteristics
consumption
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of various
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through are
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declinationinin
essentials ofthis system.
steady
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for various main challenge
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are
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essentials inthesteadyconstant is now
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transient stateis regimeswith single
reflected[3]. in
communication
remain
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is generated which is
product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the
2212-8271
To cope with© 2022thisTheaugmenting variety by
Authors. Published as ELSEVIER
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optimization the CC BY-NC-ND
by ELSEVIER
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B.V.
the existing causes difficulties regarding an efficient definition and
Peer-review
This is an under
open responsibility
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under the scientific
CC committee
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license 29th CIRP Life Cycle Engineering Conference
(https://creativecommons.org/licenses/by-nc-nd/4.0)
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 29th CIRP Life Cycle Engineering Conference
2212-8271 © 2022 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-reviewunder
Peer-review under responsibility
responsibility of the
of the scientific
scientific committee
committee of theof28th
the CIRP
29th CIRP
DesignLife Cycle Engineering
Conference 2018. Conference.
10.1016/j.procir.2022.02.032
 Shrikant Shankarrao Pawar et al. / Procedia CIRP 105 (2022) 192–197
2 Author name / Procedia CIRP 00 (2022) 000–000
highly energy intensive during the machining process. As a
result, a considerable amount of energy is consumed in transient
state of machine tool. Avoidance of this segment of energy may
result into an underestimation and inaccuracy to the total power
consumption and energy efficiency of the machine tool. A few
preliminary experiments on milling indicated that spindle
energy consumption in acceleration (SECA) account for the
largest proportion of the energy consumed in transient state [4].
In order to reduce the SECA, there is a necessity to develop a
spindle energy consumption model in idle and acceleration
stages more accurately.
Spindle acceleration is the process of spindle starting up
from standby state or achieving a higher rotational speed from
a lower one without performing any material removal
operation. The power requirement in spindle acceleration is
significantly higher with respect to the steady state, as the
torque required to accelerate the spindle system is substantially
greater than the torque required to keep it running. As the
power spike in transient state takes place for a short span of
time, the modeling of spindle energy consumption is very
difficult and complicated [3, 4]. An experimental study has
been done by Avram and Xirouchakis [3] to calculate the power
required for spindle acceleration. The torque required to
accelerate the whole spindle moment of inertia as well as the
torque required to overcome the spindle system's mechanical
losses are included in the acceleration torque. The major
drawback of this empirical study is that it is very expensive,
time consuming and outcomes are machine tool specific.
Zhong et al. [5] studied various empirical energy consumption
models of spindle rotation, spindle acceleration, feed and
material removal and proposed evaluation criteria to rank
models. Huang et al. [6] introduced an empirical model for
computing energy consumption in spindle start-up process.
Three fragment functions such as linear function, Hermite
interpolation and cubic function are assumed to fit the power
curve for prediction of energy consumption.
According to energy consumption characteristics, Jia et al.
[7, 8] identified and classified key state transitions of turning
process to develop energy demand model. The machining
transient states are described by finite state machine (FSM)
technique and the key transient state processes are identified
according to Pareto principle. Lv et al. [9] investigated on
energy efficient spindle drive system to improve static and
dynamic performance with the help of biogeography-based
optimization (BBO) algorithm. For CNC machine tools,
Pawanr et al. [10] developed empirical model based on
regression analysis to compute energy consumption during
spindle acceleration. However, these empirical models are
costly and need time-consuming experiments to acquire spindle
acceleration power data, which are then utilized to calculate
model coefficients using regression analysis. Wojcicki and
Bianchi [11, 12] carried out an investigation on energy
management of spindle subsystem for reduction of
environmental impact of the spindle run-up and run-down
operations for multi-spindle machine tools. The
aforementioned empirical models are costly, labor intensive
and time consuming. Therefore, an analytical model is required
for accurate estimation of spindle energy without conducting
actual machining experiment. On the basis upon principle of
193
spindle mechanical transmission and motor control, Lv et al.
[13] proposed an analytical model to predict energy
consumption during spindle acceleration for CNC lathe where
spindle drive system consists of induction motor and
mechanical transmission system. According to their work,
spindle acceleration finishes at the point where spindle power
reaches to the peak point neglecting the time required reaching
to target rpm. But in reality, spindle acceleration process is not
over at the time when the power spike is at its maximum value.
It continues upto the process of the beginning of the next
immediate target spindle rpm and ends at the point where the
constant idle power starts its journey at the targeted higher
spindle speed. Therefore, the time required to achieve the
maximum spindle power at the peak point and the time required
to the end of acceleration are not same. Hence, the spindle
acceleration energy consumption needs to be calculated in the
transient zone where spindle acceleration starts, reaches to its
maximum value and ends to complete the acceleration process
within the transient state. Therefore, an attempt has been made
to develop an analytical model for accurate estimation of
spindle energy consumption based on steady and transient
states in milling process.
The rest of the paper is organized as follows: Section 2
discusses formulation of spindle acceleration energy
consumption for milling. Experimental details for power
measurement have been discussed in section 3. Section 4
covers the results of computational studies and machining
experiments along with comprehensive discussions. Section 5
concludes with a summary of major contributions from the
present work.
2. Formulation of spindle acceleration energy
This section deals with mathematical formulation of spindle
acceleration energy consumption based on spindle drive and
mechanical transmission systems. It is well known fact that
energy required in spindle acceleration is much higher as
compared to steady state. The required torque for accelerating
spindle drive system as shown in Fig.1 is more than the
required torque for keeping it running. A typical power profile
of spindle acceleration of VMC is shown in Fig.2. It is observed
from the power profile graph that when the spindle begins to
accelerate, the magnitude of power consumption starts to
increase gradually. It reaches to a maximum value quickly and
after that it starts to decrease gradually. Finally, the spindle
acceleration comes to an end when spindle achieves the
immediate target speed and reaches to stable state of machine.
The time required to obtain the maximum spindle power at the
peak point from the beginning of the process and the time
required to come to an end of acceleration process with respect
to the peak point are different. Therefore, a detailed analysis is
required in the transient zone from the starting to end of
acceleration process via the peak point.
There are two major components of power required for
spindle acceleration. The first component is the power required
to sustain spindle rotation, which is equal to the spindle rotation
power at the given spindle rpm. The second component is the
power required to overcome the inertia of spindle drive system
and accelerate the spindle, which equals the product of
acceleration torque and angular speed of spindle motor. Thus,
194 Shrikant Shankarrao Pawar et al. / Procedia CIRP 105 (2022) 192–197
Author name / Procedia CIRP 00 (2022) 000–000 3

the power required for spindle acceleration (𝑊𝑊𝑆𝑆𝑆𝑆 ) is calculated 2𝜋𝜋(𝑛𝑛2 −𝑛𝑛1 )
𝑡𝑡𝑆𝑆𝑆𝑆1 = (4)
as: 60𝛼𝛼𝑀𝑀𝑀𝑀

𝑊𝑊𝑆𝑆𝑆𝑆 = 𝑊𝑊𝑆𝑆𝑆𝑆 (𝑛𝑛) + 𝑇𝑇𝑆𝑆𝑆𝑆 𝜔𝜔𝑀𝑀𝑀𝑀 (1) where 𝑛𝑛1 is the initial spindle speed before acceleration in rpm,
𝑛𝑛2 is the target spindle speed after acceleration, 𝛼𝛼𝑀𝑀𝑀𝑀 is the
where 𝑊𝑊𝑆𝑆𝑆𝑆 (𝑛𝑛) is the power required for spindle rotation, 𝑛𝑛 is angular acceleration of spindle.
spindle rpm, 𝑇𝑇𝑆𝑆𝑆𝑆 is the torque required for spindle rotation and 𝑡𝑡𝑆𝑆𝑆𝑆2 = 𝑡𝑡𝑆𝑆𝑆𝑆1 − 𝛿𝛿𝑆𝑆𝑆𝑆 (5)
𝜔𝜔𝑀𝑀𝑀𝑀 is the angular speed of motor spindle. The torque required
for spindle rotation 𝑇𝑇𝑆𝑆𝑆𝑆 can also be expressed as: 𝑃𝑃(𝑛𝑛2 )−𝑃𝑃(𝑛𝑛1 )
𝛿𝛿𝑆𝑆𝑆𝑆 = 𝑡𝑡𝑆𝑆𝑆𝑆1 . 𝑃𝑃 (6)
𝑚𝑚𝑚𝑚𝑚𝑚 −𝑃𝑃(𝑛𝑛1 )
𝑇𝑇𝑆𝑆𝑆𝑆 = 𝐽𝐽𝑆𝑆𝑆𝑆 𝛼𝛼𝑀𝑀𝑀𝑀 (2)
The moment of inertia of the spindle motor and spindle drive
where 𝐽𝐽𝑆𝑆𝑆𝑆 is the equivalent moment of inertia for the spindle
system (𝐽𝐽𝑆𝑆𝑆𝑆 ) can be calculated as follows:
drive referred to spindle motor shaft, 𝛼𝛼𝑀𝑀𝑀𝑀 is the angular
acceleration of motor spindle. 𝐽𝐽𝑆𝑆𝑆𝑆 = 𝐽𝐽𝑀𝑀𝑀𝑀 + 𝐽𝐽𝑇𝑇𝑇𝑇 (7)

where 𝐽𝐽𝑀𝑀𝑀𝑀 is the rotor moment inertia of motor spindle and

𝐽𝐽𝑇𝑇𝑇𝑇 is the equivalent moment of inertia of the spindle
transmission system of the spindle drive. By considering
spindle and pulley as hollow cylinder parts, their moment of
inertia is computed as:
𝜋𝜋𝜋𝜋𝜋𝜋(𝐷𝐷24 −𝐷𝐷14 )
𝐽𝐽𝑇𝑇𝑇𝑇 = 32
(8)
where 𝐷𝐷2 is the outer diameter, 𝐷𝐷1 is the inner diameter, 𝜌𝜌 is
the density of the shaft material and 𝐿𝐿 is the length of the shaft.
Then, the energy consumed during spindle acceleration can be
written as follows:
𝑡𝑡 𝑡𝑡
𝐸𝐸𝑆𝑆𝑆𝑆 = ∫0 𝑆𝑆𝑆𝑆1 𝑊𝑊𝑆𝑆𝑆𝑆 𝑑𝑑𝑑𝑑 + ∫𝑡𝑡 𝑆𝑆𝑆𝑆 𝑊𝑊𝑆𝑆𝑆𝑆 𝑑𝑑𝑑𝑑 (9)
𝑆𝑆𝑆𝑆1

The effectiveness of the proposed power, time, and energy

Fig.1. Spindle drive system for a milling center consumption models is validated through machining
experiments which are described in the subsequent following
sections.

3. Experimental equipment and data collections

All the experiments of spindle acceleration have been carried

Fig.2. Power profile of spindle acceleration or CNC milling machine
It is already mentioned that total spindle acceleration time
(𝑡𝑡𝑆𝑆𝑆𝑆 ) can be split into two following parts namely
𝑡𝑡𝑆𝑆𝑆𝑆 = 𝑡𝑡𝑆𝑆𝑆𝑆1 + 𝑡𝑡𝑆𝑆𝑆𝑆2
out on three axis LMW JV-40 vertical machining center
(VMC) equipped with a power logger as shown in Fig. 3. This
dedicated power logger system developed by National
Instruments was used for measurement of total power
consumption and collection of the data with the help of DAQ
system. The experimental setup for power measurement
includes voltage sensors (LEM LV25-P), current sensors (LEM
LA55-P), NI-9215 data collecting cards, a Compact DAQ card,
and a LabVIEW software interface, etc. The power
consumption for all machining experiments have been
measured at the main power supply port of electrical panel box
of the CNC machine using voltage and current transducers. The
detailed specification of the spindle drive system of the LMW
(3) JV-40 machining center is given in Table-1.

where 𝑡𝑡𝑆𝑆𝑆𝑆1 is the time required to reach the peak point during Table-1: Specification of spindle drive system
acceleration process and 𝑡𝑡𝑆𝑆𝑆𝑆2 is the time required for coming to Motor input 116-220 V
No. of poles 4
the stable state of the target spindle speed. If the spindle speed Power factor 65%
is increased from 𝑛𝑛1 to 𝑛𝑛2 , the time required for spindle Speed 8000 rpm
Motor power 5.5/7.5 kW
acceleration can be written as: Maximum Torque 32.3/58.7 Nm
 Shrikant Shankarrao Pawar et al. / Procedia CIRP 105 (2022) 192–197 195
4 Author name / Procedia CIRP 00 (2022) 000–000

4. Results and discussion

This section discusses about the experimentally measured and

predicted results obtained from computational models
developed in MATLAB software. During estimation of idle
power for various spindle speeds at stable state, the empirical
models developed in author’s earlier work [14] is used in the
present work in order to calculate spindle energy consumption.
For assessment of the effectiveness of the model, the proposed
model is first validated using the data obtained from the
machining experiments. Subsequently, the predicted results are
plotted and compared with their experimental counterpart.

Fig.3. The details of the experimental setup

For a given machine tool, the spindle acceleration is expressed

as a function of spindle speed. The initial and final spindle
speeds are decided on the basis upon process parameters and
machining conditions. Later on, the spindle acceleration is
calculated at the transient state of these spindle speeds at that
instant. The spindle speed are selected based on the three
different types of speed variation situations including spindle
ON/OFF, spindle rpm hold. The details of the variation of
spindle speed are given in the Table-2.The signals are sampled
at a frequency of 10 kHz and the power values are recorded in
the interval of 0.2 s.
Table 2. Variation of spindle speed in rpm
Type 1 Type 2
Time elapsed (s)
Fig. 4. Predicted and measured spindle energy (SE)
For assessment of effectiveness of the proposed model, the
predicted results are compared with their measured
counterpart. On the basis upon the predicted results, the
proposed model is validated. The estimated spindle energy
(SE-1) of earlier model [13] are also compared with the results
of the proposed model (SE-2). From Fig. 4, it is observed that
Type 3 both models are able to estimate spindle energy (SE)
consumption but the proposed model gives better results.

Time elapsed (s)

Time elapsed (s)

Spindle speed
Spindle speed

Spindle speed
Spindle stop

Spindle stop

Spindle stop
Parameters
Sr. No.

(rpm)

(rpm)

(rpm)

Initial speed 0 5 Y 0 5 Y 0 5 Y
1
Succeeding 1000 5 - 5000 25 Y 1000 5 Y
speed
Preceding 1000 - - 0 - -
2 speed
Succeeding 2000 5 - 2000 5 Y
speed
Preceding 2000 - - 0 - -
3 speed
Succeeding 3000 5 - 3000 5 Y
speed
Preceding 3000 - - 0 - -
4 speed Fig. 5. Comparison of predicted and measured spindle energy
Succeeding 4000 5 - 4000 5 Y
speed
Preceding 4000 - - 0 - -
As shown in Fig. 5, the prediction accuracy of spindle energy
5 speed consumption is 98.43% considering spindle stable and transient
Succeeding 5000 5 Y 5000 5 Y states. The measured spindle energy (SE) is 8867 J when
speed spindle speed changes from 1000 to 2000 rpm for a total
spindle holding time of 10 secs. For same machining
conditions, the estimated spindle energy is 9005 J based on
proposed model. The spindle energy consumption based on
earlier model [13] is also calculated which is 8447 J. The
196 Shrikant Shankarrao Pawar et al. / Procedia CIRP 105 (2022) 192–197
Author name / Procedia CIRP 00 (2022) 000–000
prediction accuracy is also determined based on the earlier
model and it is 95.27%. The prediction accuracy is increased
from 95.27% to 98.43% based on proposed model.
a
Fig.6. Variation of spindle power consumption at various rpm without
spindle stop a) measured b) predicted
Fig.6 shows the variation of spindle power for various
spindle speeds without stopping of spindle rotation during
change in spindle speed from the lower to higher value. It is
observed that the magnitude of power spike increases when
spindle speed change takes place between two consecutive
spindle rpm. The power spike is higher when speed change
happens between two higher rpm with respect to the change of
rpm between two lower rpm. As the torque required for spindle
rpm is higher, the power spike is larger for two higher
consecutive rpms, leading to more energy consumption.
Fig.7 shows the comparison of the measured and predicted
spindle acceleration energy consumption when spindle speed
changes from 4000 to 5000 rpm. From the measured and
predicted results, it is clearly seen that the nature of the power
profile in the transient and steady state zone is similar. The
predicted results are good in agreement with their measured
counterpart results.
5
a
Fig. 7. Spindle acceleration energy consumption at 5000 rpm a)
measured b) predicted
Fig.8 shows the variation of spindle power for various spindle
speeds with spindle hold. It starts from zero and reaches to
target rpm. During stopping of spindle rpm, the deceleration
state is also very prominent where the negative power spike
takes place in opposite direction. The spindle deceleration is
controlled by a spindle motor inverter through reduction of
electrical frequency. The kinetic energy of spindle is
transformed back into electrical energy, which is absorbed by
dynamic braking resistor. Therefore, negative power spike is
observed in deceleration state. But, the magnitudes of power
spike from zero to immediate target rpm and target rpm to zero
are different in values. The similar trend in power spike is also
observed in deceleration state. It is also observed that the
magnitude of power spike increases when spindle speed change
takes place between two consecutive spindle rpm. During
change of spindle speed, the magnitude of power spike between
two higher rpm is larger as compared to the power spike
between two lower rpm. As the torque required for spindle rpm
is higher, the magnitude of power spike is larger for two higher
consecutive rpms, leading to more energy consumption. The
power spike is lesser in deceleration as compared to
acceleration stage. It is probably due to less amount of
frictional torque responsible in deceleration stage.
 Shrikant Shankarrao Pawar et al. / Procedia CIRP 105 (2022) 192–197
6 Author name / Procedia CIRP 00 (2022) 000–000
a
b is more prominent and the magnitude of power spike is larger
Fig.8. Variation of spindle power consumption at various rpm with
spindle stop a) measured b) predicted
a emissions: a bilevel optimization approach, Energies, 7 (2014):2228-2245.
b consumption of machine tools in the spindle start-up process before
Fig.9. Power consumption during spindle acceleration a) measured b)
predicted
Fig.9 shows the variation of spindle power at transient and
stable state for various spindle speeds. It is observed that at
higher rpm, the duration of transient state increases and
steady state decreases. In similar manner, at lower rpm, the
duration of transient state decreases and steady state
increases. At higher rpm, spindle energy consumption is more
due to larger value of transient and steady state. At higher
rpm, torque required to overcome the friction as well as
197
torque required for moment of inertial are more resulting into
more torque and respective more spindle energy
consumption.
5. Conclusion
The current paper discusses about the modelling of spindle
energy consumption during acceleration stage for accurate
prediction of total energy consumption during milling. The
proposed analytical model is able to estimate the spindle energy
consumption with an accuracy of almost 98 %. When spindle
speed increases from the lower to higher one, the power spike
when the initial spindle rpm is more for constant change of
spindle rpm due to requirement of more torque. Therefore, this
analytical model helps to estimate the spindle energy
consumption more accurately considering the power spike of
acceleration in transient state of machine. The present study is
also helpful to contribute significantly towards energy efficient
manufacturing system.
Acknowledgements
The authors thank and acknowledge the Science and Engineering Research
Board (SERB), Department of Science and Technology (DST), Government of
India for providing financial support to carry out this research work (Project
No: SB/FTP/ETA-03/2013).
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