energies

Article
Establishment of an Improved Material-Drilling
Power Model to Support Energy Management of
Drilling Processes
Shun Jia 1,2, *, Qingwen Yuan 1, *, Wei Cai 3 , Qinghe Yuan 2, *, Conghu Liu 4 , Jingxiang Lv 5
and Zhongwei Zhang 6
1 Department of Finance and Economics, Shandong University of Science and Technology, Jinan 250031, China
2 Department of Industrial Engineering, Shandong University of Science and Technology,
Qingdao 266590, China
3 College of Engineering and Technology, Southwest University, Chongqing 400715, China;
weicai@swu.edu.cn
4 School of Mechanical and Electronic Engineering, Suzhou University, Suzhou 234000, China;
liuconghu@sjtu.edu.cn
5 Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education,
Northwestern Polytechnical University, Xi’an 710072, China; youyilong@zju.edu.cn
6 Department of Mechanical Manufacturing and Automation, Henan University of Technology,
Zhengzhou 450001, China; zzw_man@haut.edu.cn
* Correspondence: herojiashun@163.com or jiashun@sdust.edu.cn (S.J.); Tiger_yuan@163.com (Q.Y.);
yuan_qinghe@sina.com (Q.Y.); Tel.: +86-532-860-57044 (S.J.)




Received: 2 July 2018; Accepted: 31 July 2018; Published: 2 August 2018


Abstract: Drilling processes, as some of the most widely used machining processes in the
manufacturing industry, play an important role in manufacturing process energy-saving programs.
However, research focus on energy modeling of drilling processes, especially for the modeling
of material-drilling power, are really scarce. To bridge this gap, an improved material-drilling
power model is proposed in this paper. The obtained material-drilling power model can improve
the accuracy of the material-drilling power and lay a good foundation for energy modeling and
optimization of drilling processes. Finally, experimental studies were carried out on an XHK-714F
CNC machining center (Hangzhou HangJi Machine Tool Co., Ltd., Hangzhou, China) and a JTVM6540
CNC milling machine (Jinan Third Machine Tool Co., Ltd., Jinan, China). The results showed that
predictive accuracies with the proposed model are generally higher than 96% for all the test cases.

Keywords: drilling process; material-drilling power; energy management

1. Introduction
Nowadays, climate change has become one of the most imperative topics [1]. Manufacturing
processes are partially responsible for climate change due to the emissions generated as a result
of energy consumption [2]. According to International Energy Outlook 2017 [3], the industrial
sector (including manufacturing, mining, and so forth) accounts for about 50% of the world’s
energy use. World industrial sector energy use will increase by 18% from 2015 to 2040, reaching
280 quadrillion British thermal units (Btu) by 2040, as shown in Figure 1 [3]. Manufacturing activities
and production processes play a major role in industrial energy consumption, and are responsible
for approximately 90% of the energy consumption in the industrial sector [4]. It has been pointed
out that the manufacturing industry has a remarkable energy-saving potential [5]. More specifically,
the worldwide manufacturing industries’ energy-saving potential is estimated to be 20% through

Energies 2018, 11, 2013; doi:10.3390/en11082013 www.mdpi.com/journal/energies

Energies 2018,
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Energies 2018, 11,
11, x2013
x FOR
FOR PEER
PEER REVIEW
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16

worldwide manufacturing
worldwide manufacturing industries’
industries’ energy-saving
energy-saving potential
potential is
is estimated
estimated toto be
be 20%
20% through
through 2050
2050
2050
[6]. [6]. Therefore,
Therefore, energyenergy efficiency
efficiency improvement
improvement of of
the the manufacturing
manufacturing industry
industry is
[6]. Therefore, energy efficiency improvement of the manufacturing industry is identified as an is identified
identified as as
an
an important
important path
path for for energy
energy savings
savings and
and climate
climate change
change mitigation
mitigation
important path for energy savings and climate change mitigation [1]. [1].
[1].

year
year

Figure 1.
Figure 1.
Figure World energy consumption
World energy
1. World energy consumption by
consumption by end-use
by end-use sector
sector [3].
[3].

Manufacturing systems
Manufacturing
Manufacturing systems
systems are are complex entities
are complex
complex entities with
entities with multiple
with multiple subsystems
multiple subsystems that
subsystems that interact
that interact
interact
dynamically [7].
dynamically
dynamically [7]. Machining
[7]. Machining systems,
Machining systems,
systems, as as some
as some
some of of the most
of the
the most important
most important and
important and widespread
and widespread subsystems
widespread subsystems in
subsystems in
in
manufacturing
manufacturing
manufacturing[8], [8], play
[8],play a key
playaakey role
keyrole in energy-saving
roleininenergy-saving
energy-savingfor for the
forthe manufacturing
themanufacturing
manufacturing industry
industry
industry [9].
[9]. Moreover,
Moreover,
[9]. Moreover, aa
study
study
a studyconducted
conducted by Gutowski
conductedbybyGutowski showed
Gutowskishowed a
showedaavery very interesting
veryinteresting result
interestingresult [10]:
result [10]: CO
[10]: CO emissions
CO22 emissions
2
emissions of of one
of one computer
one computer
computer
numerical
numerical control
control (CNC)
(CNC) machine
machine tool
tool (22
(22 kW
kW spindle
spindle power)
power) in
in one
one year
year
numerical control (CNC) machine tool (22 kW spindle power) in one year are equivalent to the are
are equivalent
equivalent to
to the CO
the CO22
CO 2
emissions
emissions
emissions ofof 61
of 61 SUVs
61 SUVs (20.7
SUVs (20.7 mpg,
(20.7mpg, 12,000
mpg,12,000 miles/year).
12,000miles/year). When
miles/year).When When it comes
it comes
it comes to SO
to to
SOSO and
2 and
2 NO
NO
and emissions,
x emissions,
x
NO as
as
emissions,
2 x
shown
shown
as in Figure
in
shown Figure
in Figure2, one
2, one
2, CNC
CNC
one CNC machine
machine
machine tool
tool isisequivalent
is
tool equivalent toto248
equivalentto 248 SUVs
248SUVs and
SUVsand and3434 SUVs,
34SUVs, respectively
SUVs,respectively [10].
respectively[10].
[10].
It can
It
It can be
can be seen
be seen that
seen that energy
that energy consumption
energy consumption and
consumption and carbon
and carbon emissions
carbon emissions of
emissions of machine
of machine tools
machine tools are
tools are significant.
are significant.
significant.

300
300
248
248
250
250
SUVs
ofSUVs

200
200

150
Numberof

150
Number

100
100
61
61
50
50
34
34
00
CC OO 22 SS OO 22 NN OO XX
Machine tool
Machine tool emissions
emissions

Figure 2.
Figure Machine tool
2. Machine tool emissions
emissions compared
compared with
with SUVs
SUVs [10].
[10].

Unfortunately, extensive
Unfortunately,
Unfortunately, extensive studies
extensive studies have
studieshave revealed
haverevealed that
revealedthat the
thatthe energy
theenergy efficiency
energyefficiency
efficiencyofof
of machine
machine
machine tools
tools
toolsis
is
generally
generally
is generally less than
lessless
than 30%
than30% [11–13].
30%[11–13]. Therefore,
[11–13].Therefore, the energy
Therefore,thetheenergy saving
energysaving potential
savingpotential of machine
potentialofof machine tools
machine toolstools is is
is
remarkable and
remarkable
remarkable andenergy
and energy
energy efficiency
efficiency
efficiency improvement
improvement
improvement of machining
of machining
of machining processes
processes
processes has become
has
has become become
a notableaa research
notable
notable
research
research area. Extensive
area. Extensive
area. Extensive existing
existing existing studies
studies
studies have have focused
have focused
focused on energy on energy
onmodeling modeling
energy modeling
and energy and energy
and savings savings
energy savings
of turning of
of
turning
turning processes
processesprocesses [14], milling
[14], processes
[14], milling processes
milling processes
[15,16], and[15,16],
[15,16], and grinding
and processes
grinding processes
grinding processes [17]. Drilling,
[17]. as
[17]. Drilling, Drilling, as
as an
an important an
important
important machining
machining process,
process, plays
plays aa significant
significant role
role in
in the
the energy
energy management
management
machining process, plays a significant role in the energy management of machining processes [18]. of
of machining
machining
processes [18].
processes
However, [18]. However,
However,
the energy the energy
the
modeling energy modeling
modeling
method focusedmethod
method focused
focused
on drilling on drilling
on drilling
processes, processes,
processes,
especially especially
for especially
the modeling for
for
thematerial-drilling
the
of modeling of
modeling of material-drilling
material-drilling power,
power, has power,
not beenhaswell
has not been
not been well
studiedwell[19].
studied
studied [19].
The[19]. The material-drilling
The material-drilling
material-drilling power
power power
is the
is
is the
tool-tiptool-tip
the tool-tip
cutting cutting
cutting
power, power,
power, and
and isand is solely
is solely
solely relatedrelated
related to the
to thetomaterial material
the material removal
removal
removal during during
during drilling
drilling
drilling process
process
process [20].
[20]. The
[20]. The material-drilling
material-drilling power,
power, as as an
an important
important partpart of of total
total drilling
drilling power,
power, establishing
establishing its its
Energies 2018, 11, 2013 3 of 16

The material-drilling power, as an important part of total drilling power, establishing its accurate
power model is important for the energy modeling and energy optimization of the drilling processes.
Up to now, research focused in particular on modeling of material-drilling power is really rare. To fill
this gap, an improved material-drilling power model is established to support energy modeling
and optimization of drilling processes. The advantages of this research are summarized as follows:
(i) an improved material-drilling power model can be established for improving the prediction
accuracy of drilling power; (ii) the obtained power model can lay a good foundation for energy
modeling and optimization of drilling processes; (iii) material-drilling power, as a crucial part of
total drilling power, the establishment of its power model can improve the transparency of energy
consumption and help us to better understand energy characteristics during drilling processes.

2. Literature Review
Triggered by the necessity to improve the energy efficiency and environmental friendliness and
reduce the energy-related costs of the manufacturing industry, extensive studies have been conducted
in term of energy monitoring [21–23], energy modeling and carbon-emission evaluating [24–26], energy
optimization and energy efficiency improvement [27–30], energy benchmarking [31,32], and solid
waste reduction [33] of the manufacturing industry. Turning, milling, drilling and grinding processes
are widely used in the manufacturing industry [8]. Unfortunately, a large number of existing studies
have shown that the energy efficiencies of the above machining processes are generally less than
30% [11–13,34]. Therefore, extensive existing studies have been carried out focused specially on
energy modeling and the energy saving potential of turning [35,36], milling [37–40], grinding [41,42],
and sandcasting processes [43]. When it comes to drilling processes, the existing energy-related
researches mainly focused on the micro-drilling processes [44], which are usually used for the
manufacturing of the cooling holes in jet turbines blades, micro-holes in automotive fuel injection
systems and so forth [45]. In order to help the operators decide on process parameters of micro-drilling
process, an effective energy-saving strategy was devised for micro-drilling [46]. Moreover, for electrical
discharge machining (EDM) drilling, as one of the most used micro-drilling processes, the specific
electricity requirement is expressed as a function of the rate of material processed, as shown in
Figure 3 [47]. However, the power required for EDM drilling in Figure 3 is an approximate value
rather than an exact value, and the power is assumed to be 75% of rated power for EDM drilling [47].
It is necessary to point out that the energy consumption characteristics of the micro-scale drilling
are significantly different from those of the traditional drilling process. The energy involved in material
removal in micro-scale machining is negligible compared to the energy consumed by the machine
module [45]. For the traditional drilling process, the energy involved in material removal is much
more important, and the material-drilling power is an important part of the total drilling power.
However, the power model of the drilling process, especially for the material-drilling power, has not
been well studied. The theoretical material-drilling power can be calculated based on the manual
of machining process [48,49]. However, the actual material-cutting power includes not only the
theoretical material-drilling power but also the additional loss power, which is involved with the
drilling cutters, drilling parameters, machine tools and workpiece [19]. Research specially focused
on the material-drilling power is really rare. In our previous study [19] we tried to establish a simple
material-drilling power model, however, the accuracy and the effectiveness of the material-drilling
power model needs to be further improved. Consequently, an improved material-drilling power model
is proposed in this paper to improve the material-drilling power predictive accuracy. The outcomes of
this study can improve the transparency of energy consumption and help us to better understand the
energy characteristics of drilling processes.
Energies 2018, 11, 2013 4 of 16
Energies 2018, 11, x FOR PEER REVIEW 4 of 16

1×1012

1×1011

1×1010

Electricity Requirement [J/cm3 ]

1×109

1×108

1×107

1×106

1×105

1×104

1×103

1×102
1×10-7 1×10-5 1×10-3 1×10-1 1×101 1×103

Figure 3. Specific electricity requirements for various manufacturing processes as a function of the
Figure 3. Specific electricity requirements for various manufacturing processes as a function of the rate
rate of material processed [47].
of material processed [47].
3. Methodology
3. Methodology
3.1. Composition of Material-Drilling Power
3.1. Composition of Material-Drilling Power
The material-drilling power is defined as the tool-tip cutting power during drilling process,
The
which material-drilling
is solely relatedpowerto theis material
defined as the tool-tip
removal cutting
[20]. The power duringpower
material-drilling drilling process,
( Pmd ) is anwhich
is solely relatedpart
important to the material
of total removal
drilling power [20].
( PTD The
) duringmaterial-drilling power
material cutting. (Pmd ) is
As shown in an important
Figure 4. The part
of total drilling
total drillingpower
power(P isTD ) duringof
composed material
power ofcutting.
standbyAs shown in
operation ( PFigure 4. The
so ), power total drilling
of spraying power
cutting
is composed
flood ( Psf of ),power
powerofofstandby
spindle operation
rotation ( P(P
sr ),
so ), power
power of
of spraying
Z-axis cutting
feeding ( Pzf flood
) and (P
power
sf ), power
of of
spindle rotation
material-drilling(P ), power of Z-axis feeding
sr ( Pmd ). The power of standby (P ) and power of material-drilling
z f operation Pso is the power consumed (P ). The
md by the power
of standby operation Pso is the power consumed by the various basic modules
various basic modules (i.e., NC (Numerical control) system, display, fans, etc.) to ensure (i.e., NC (Numerical
the
control) system, display, fans, etc.) to ensure the operational readiness. The power
operational readiness. The power of spraying cutting flood Psf is related to the cooling device, of spraying cutting
flood Ps f is related to the cooling device, which is turned on during drilling processes. The power of
which is turned on during drilling processes. The power of spindle rotation Psr refers to the
spindle rotation Psr refers to the power needed to guarantee the rotation of the spindle. The power of
power needed to guarantee the rotation of the spindle. The power of Z-axis feeding Pzf is the
Z-axis feeding Pz f is the power consumed by the feed driving system during Z-axis feeding. The power
power consumed by the feed driving system during Z-axis feeding. The power models of standby
models of standby operating, spraying cutting flood, spindle rotating and Z-axis feeding have been
operating, spraying cutting flood, spindle rotating and Z-axis feeding have been researched in our
researched in our previous work [19,20], so the establishment of the above P power models (P , P ,
previous work [19,20], so the establishment of the above power models ( Pso , sf , Psr and Pzf so) s f
Psr and Pz f ) are out of the scope of this paper while the establishment of the material-drilling power
are out of the scope of this paper while the establishment of the material-drilling power model
model (Pmd ) is the focus in this paper. Moreover, the standby operating power, spraying cutting flood
( P ) is the focus in this paper. Moreover, the standby operating power, spraying cutting flood
power, md spindle rotating power, Z-axis feeding power constitute the air cutting power (Pair ), which is
power, spindle rotating power, Z-axis feeding power constitute the air cutting power ( Pair ), which
the power consumed while the cutter approaching the workpiece with the designed tool path and
is the power consumed while the cutter approaching the workpiece with the designed tool path and
cutting parameters before actual material removal [35]. Therefore, the material-drilling power Pmd
cutting parameters before actual material removal [35]. Therefore, the material-drilling power
can beP obtained by subtracting the air cutting power Pair from the total drilling power PTD . More
md can be obtained by subtracting the air cutting power Pair from the total drilling power PTD .
specifically, the material-drilling power can further be divided into two parts: theoretical cutting power
More specifically, the material-drilling power can further be divided into two parts: theoretical
(PTcut ) and additional loss power (PAloss ). The detailed modeling approach will be discussed in the
next subsection.
Energies 2018, 11, x FOR PEER REVIEW 5 of 16

cutting power ( PTcut ) and additional loss power ( PAloss ). The detailed modeling approach will be
Energies 2018, 11, 2013 5 of 16
discussed in the next subsection.

spindle
acceleration feeding 1stdrilling 2nddrilling
startup
Power (w)
cutting
air cutting air cutting
flood
startup
Pmd PTcut+PAloss
Psr +Pzf
standby
Pair Psf PTD

Pso

tstandby tsetup tair tmd tair tmd Time (s)

Figure 4.
Figure Power profile
4. Power profile of
of aa machine
machine tool
tool during
during drilling
drilling processes.
processes.

3.2.
3.2. Improved
Improved Material -Drilling Power Model
Material-Drilling
As
As mentioned
mentioned above,above, the
the material-drilling
material-drilling power
power cancan be be divided
divided into
into two parts: (a)
(a) theoretical
theoretical
cutting
cutting power (P ( PTcut
Tcut ),
), and
and (b)
(b) additional
additional loss
loss power
power (P( P ).
Aloss
Aloss ). Hence,
Hence, the
the material-drilling
material-drilling power
power cancan
be
expressed
be expressedas:as:
Pmd = PTcut + PAloss (1)
Pmd  PTcut  PAloss (1)
where Pmd is material-drilling power, W; PTcut is theoretical drilling power, W; PAloss is additional loss
power, W.
where Pmd is material-drilling power, W; PTcut is theoretical drilling power, W; PAloss is
additionaltheoretical
The loss power, W. power PTcut is the cutting power of the tool tip acting on the workpiece,
drilling
which is the theoretical
The theoretical drilling and minimum
power Ppower needed to ensure the material removal, and is related
Tcut is the cutting power of the tool tip acting on the
to the cutterwhich
workpiece, material,
is theworkpiece
theoretical material and cutting
and minimum powerparameters.
needed toInensure
addition,
the the additional
material loss
removal,
power P is the power loss of the machine tool caused by the cutting load
Aloss to the cutter material, workpiece material and cutting parameters. In addition, the
and is related on the cutting tool.
additional of
The value thepower
loss additional lossispower
PAloss depends
the power losson
of the
thestructure
machine and toolenergy
causedcharacteristic
by the cuttingof machine
load on
tool. Moreover, the additional loss power PAloss can be calculated as a linear function of the theoretical
the cutting tool. The value of the additional loss power depends on the structure and energy
cutting power P [50]. Therefore, the additional loss power can be expressed as:
characteristic of Tcut
machine tool. Moreover, the additional loss power PAloss can be calculated as a
linear function of the theoretical cutting power
PAloss = α0 P[50].
PTcut
Tcut
Therefore, the additional loss power can
(2)
be expressed as:
where α0 is additional power loss coefficient.
PAloss
According to Equations (1) and (2), the  0 PTcut
material-drilling power can further be calculated as: (2)

where  0 is additional power

Pmd = Ploss coefficient.
Tcut + PAloss = PTcut + α0 PTcut = (1 + α0 ) PTcut (3)
According to equations (1) and (2), the material-drilling power can further be calculated as:
More specifically, the theoretical drilling power can be computed as [48,49]:
Pmd  PTcut  PAloss  PTcut  0PTcut  (1  0 )PTcut (3)
2πn
PTcut = Mω = (C M dz M f y M k M ) (4)
More specifically, the theoretical drilling power can be computed 60 as [48,49]:

where M is drilling torque, N·m; ω is rotation angular 2 n of the cutting tool, rad/s; C M and k M
velocity
PTcut  M   (CM d z f y kM ) M M
(4)
60
are correction coefficients related to the cutter material, workpiece material and cutting conditions; d is
drill diameter, mm; z M is exponent of the drill diameter; f is feed rate, mm/r; y M is exponent of the
where M is drilling torque, N·m;  is rotation angular velocity of the cutting tool, rad/s; CM
feed rate; n is spindle speed, r/min. The theoretical drilling power is the minimum power to ensure
and kM are removal.
the material correction coefficients
However, related to loss
the additional the power
cutter material,
of machine workpiece material
tool caused by the and cutting
cutting load
conditions; d is drill
was not considered in diameter, mm; drilling
the theoretical zM is exponent of the drill
power. Therefore, theoreticalf drilling
thediameter; is feedpower
rate, mm/r;
is not
machine of the feed rate; n is spindle speed, r/min. The theoretical drilling power is the
tool dependent.
yM is exponent
Energies 2018, 11, 2013 6 of 16

According to Equations (3) and (4), the material-drilling power can be written as:

2πn π (1 + α0 ) C M k M z M y M
Pmd = (1 + α0 ) PTcut = (C M dz M f y M k M ) = d f n (5)
60 30
For a given combination of machine tool, workpiece material and cutting tool, the values of the
π (1+ α0 ) C M k M
30 z M and y M are constant. Therefore, the material-drilling power can also be expressed as:
,

Pmd = λ D1 dαD1 f β D1 n (6)

0 M M π (1+ α ) C k
where λ D1 , α D1 and β D1 are constants and set λ D1 = 30 , α D1 = z M and β D1 = y M . It can
be seen that the material-drilling power Pmd is a function of drill diameter, feed rate and spindle
speed. In addition, the exponents of the drill diameter, feed rate and spindle speed are α D1 , β D1 and
1, respectively.
According to the experimental research of literature [51], the material-drilling power was
expressed as the function of feed rate ( f ) and cutting speed (vc ).
y
Pmd = CF f x vc (7)

where CF is correction coefficient; f is feed rate, mm/r; vc is cutting speed, m/min; x is exponent of
the feed rate; y is exponent of the cutting speed.
For drilling process, the cutting speed can be calculated as:

nπd
vc = (8)
1000
where n is spindle speed, r/min; d is drill diameter, mm.
According to Equations (7) and (8), the material-drilling power can further written as:

nπd y π y y x y
Pmd = CF f x ( ) = CF ( ) d f n (9)
1000 1000
π y
Similarly, CF ( 1000 ) , x and y are constants. Consequently, the material-drilling power is also
a function of drill diameter, feed rate and spindle speed. However, in this model, the value of exponent
of the spindle speed is y (the value of y may not be 1, and y = 0.77 was obtained for the given
combination of machine tool, cutter and workpiece in [51]), and is equal to the exponent of the drill
diameter. Based on the preliminary experimental data of our research group, the changing trend of
material-drilling power with respect to drill diameter and spindle speed is shown in Figure 5. It can
be seen that the material-drilling power Pmd increases with the increase of the spindle speed n and
drill diameter d. However, the degree of the influence is different. Thus, the exponent of the spindle
speed and the drill diameter should be different. That is to say, the exponent of the spindle speed in
the material-drilling power model will be a value that is not necessarily equal to 1 and different from
the exponent of the drill diameter.
Energies 2018, 11, 2013 7 of 16
Energies 2018, 11, x FOR PEER REVIEW 7 of 16

Pmd changes with drill diameter and spindle speed

Figure 5. Pmd changes with respect to drill diameter and spindle speed (f = 0.08mm/r).
Figure 5. Pmd changes with respect to drill diameter and spindle speed (f = 0.08 mm/r).

According to the above analysis, an improved material-drilling power model can be proposed
According to the above analysis, an improved material-drilling power model can be proposed on
on the basis of Equation (6). The improved material-drilling power model is written as:
the basis of Equation (6). The improved material-drilling power model is written as:
Pmd  D2 d  D 2 αf D 2 nβ D 2 γ (10)
Pmd = λ D2 d D2 f D2 n D2 (10)
where  is the coefficient of the improved material-drilling power model; d is the drill
where λ D2D 2is the coefficient of the improved material-drilling power model; d is the drill diameter, mm;
diameter, mm;  D 2 is the exponent of the drill diameter in the improved power model; f is feed
α D2 is the exponent of the drill diameter in the improved power model; f is feed rate, mm/r; β D2 is
rate, mm/r; 
exponent of the feedexponent
is rate in theofimproved
the feed rate
power in model;
the improved power
n is spindle model;
speed, r/min;n isγ spindle speed,
D 2 D2 is exponent
r/min;
of  D 2 isspeed
the spindle exponent ofimproved
in the the spindle speedmodel.
power in the λimproved
D2 , α D2 , β power γD2 are all
D2 , andmodel. ,  D 2 ,  and
D 2constants D 2 , and
the
 D 2 are all constants and the values of the above constants are determined by the combination of
values of the above constants are determined by the combination of machine tool, cutter material and
workpiece
machine tool, material,
cutter which
material areand
extremely
workpiece difficult to bewhich
material, obtained by theoretical
are extremely analysis.
difficult to beThus,
obtainedthe
values of these constants will be obtained by pre-experiments and statistical
by theoretical analysis. Thus, the values of these constants will be obtained by pre-experiments and analysis. The proposed
material-drilling
statistical analysis. power
The model
proposedconsiders both the theoretical
material-drilling power model drillingconsiders
power and the the
both additional loss
theoretical
power.
drilling The
power additional
and the loss powerloss
additional depends
power.onThethe additional
structure and loss energy
power characteristic
depends on the of structure
machine
tool. Consequently, the proposed material-drilling power model is
and energy characteristic of machine tool. Consequently, the proposed material-drilling power machine tool dependent. It is
necessary to point out
model is machine toolthat the limitation
dependent. of the proposed
It is necessary to point model is that
out that thethe coefficients
limitation in the
of the model
proposed
will be different under different combinations of machine tools, cutting tools,
model is that the coefficients in the model will be different under different combinations of machine and workpiece materials.
Consequently,
tools, cutting the pre-experiments
tools, and workpiece and statisticalConsequently,
materials. analysis need to thebepre-experiments
repeated to obtained and the model
statistical
coefficients
analysis need when it applies
to be repeated totoother combination
obtained the model of machine
coefficientstool,when
cutting tool, and
it applies toworkpiece material.
other combination
of machine tool, cutting tool, and workpiece material.
4. Experimental Study
4. Experimental
4.1. Study
Design of Experiments
In order
4.1. Design to show the validity of the improved material-drilling power model, experimental
of Experiments
studies were conducted on a XHK-714F CNC machining center (Hangzhou HangJi Machine Tool
In order to show the validity of the improved material-drilling power model, experimental
Co., Ltd., Hangzhou, China) and a JTVM6540 CNC milling machine (Jinan Third Machine Tool Co.,
studies were conducted on a XHK-714F CNC machining center (Hangzhou HangJi Machine Tool
Ltd., Jinan, China). The rated power of the spindle motor of the XHK-714F CNC machining center is
Co., Ltd., Hangzhou, China) and a JTVM6540 CNC milling machine (Jinan Third Machine Tool Co.,
7.5 kW and the rapid-positioning speeds of X, Y, and Z-axis are 12,000, 12,000, and 10,000 mm/min,
Ltd., Jinan, China). The rated power of the spindle motor of the XHK-714F CNC machining center is
respectively. For the JTVM6540 CNC milling machine, the rated power of the spindle motor is 4.0 kW
7.5 kW and the rapid-positioning speeds of X, Y, and Z-axis are 12,000, 12,000, and 10,000 mm/min,
and the rapid-positioning speeds of X, Y, and Z-axis are all 6000 mm/min. Based on to the improved
respectively. For the JTVM6540 CNC milling machine, the rated power of the spindle motor is 4.0
material-drilling power model, the experimental design parameters are selected as the drill diameter
kW and the rapid-positioning speeds of X, Y, and Z-axis are all 6000 mm/min. Based on to the
d, feed rate f, and spindle speed n. According to the machining process manual, the recommended
improved material-drilling power model, the experimental design parameters are selected as the
drill diameter d, feed rate f, and spindle speed n. According to the machining process manual, the
Energies 2018, 11, 2013 8 of 16

Energies 2018, 11, x FOR PEER REVIEW 8 of 16

cutting parameters of the cutter, and the machine tool performance [19,48,49], the drilling parameters
recommended
and their levelscutting parametersasofshown
were determined, the cutter, and1.the machine tool performance [19,48,49], the
in Table
drilling parameters and their levels were determined, as shown in Table 1.
Table 1. Drilling parameters and their levels.
Table 1. Drilling parameters and their levels.
Variables Level 1 Level 2 Level 3
Variables Level 1 Level 2 Level 3
Drill diameter d (mm) 8 10 12
Drill diameter d (mm) 8 10 12
Feed rate f (mm/r) 0.06 0.08 0.10
Feed rate f (mm/r) 0.06 0.08 0.10
Spindle speed n (r/min) 450 550 650
Spindle speed n (r/min) 450 550 650

Based on on the
the number
number of of the
the drilling
drilling parameters
parameters and and levels
levels of
of the 13
Based the experiment,
experiment, aa L27 L27 (3
(313))
orthogonal table
orthogonal table was
wasused
usedtotoarrange
arrangethetheexperiments.
experiments. The selected
The selectedcutter is aisparallel
cutter shank
a parallel twisttwist
shank drill
manufactured by NACHI Company (Tokyo, Japan) and the drill point ◦
drill manufactured by NACHI Company (Tokyo, Japan) and the angle
drill ispoint
118 .angle
The material
is 118°.ofThe
the
workpiece
material offor
theexperiments
workpiece foris 45# steel and the
experiments shape
is 45# of the
steel andworkpiece
the shapeisof150the×workpiece
150 × 30 mm.
is 150Moreover,
× 150 ×
themm.
30 drilling condition
Moreover, theisdrilling
wet cutting and the
condition ordinary
is wet cuttingwater baseordinary
and the emulsion was base
water usedemulsion
as the cutting
was
fluid. as
used In the
order to measure
cutting fluid.the
In material-drilling
order to measure power during experiments,
the material-drilling a power-energy
power acquisition
during experiments, a
system has been established by our research group [36]. As shown in Figure
power-energy acquisition system has been established by our research group [36]. As shown in 6, the power-energy
acquisition
Figure 6, thesystem is mainly acquisition
power-energy composed of one compactDAQ
system crate, twoofNI-9215
is mainly composed (National Instruments,
one compactDAQ crate, two
Austin, TX,
NI-9215 USA) data
(National collectionAustin,
Instruments, cards, TX,
one USA)
sensordata
power supply,cards,
collection three one
voltage sensors,
sensor powerand three
supply,
current sensors. The experiments were conducted on the XHK-714F CNC
three voltage sensors, and three current sensors. The experiments were conducted on the XHK-714Fmachining center and
JTVM6540
CNC CNC milling
machining center machine,
and JTVM6540respectively.
CNC Simultaneously,
milling machine, therespectively.
power-energy acquisition system
Simultaneously, the
was connectedacquisition
power-energy with the machine
system was toolconnected
and the power
with theandmachine
energy tool
dataandduring experiments
the power were
and energy
recorded
data duringonce every 0.1 s.were recorded once every 0.1 s.
experiments

LabVIEW Interface

CNC machining center

XHK-714F Current Sensors

Data Collecting Card

NI-9215
Sensor Power Supply
CNC milling machine
JTVM6540

Drill
Voltage Sensors
CompactDAQ Crate

Figure
Figure 6.
6. Experimental
Experimental setup
setup of
of power-energy
power-energy acquisition
acquisition system.
system.

4.2. Results and Discussion

4.2. Results and Discussion
The values of material-drilling power during the experiments can be obtained by using the
The values of material-drilling power during the experiments can be obtained by using the
power-energy acquisition system shown in Figure 6. The measured material-drilling power under
power-energy acquisition system shown in Figure 6. The measured material-drilling power under
different combinations of drilling parameters for the XHK-714F CNC machining center and
different combinations of drilling parameters for the XHK-714F CNC machining center and JTVM654
JTVM654 CNC milling machine are shown in Table 2. In order to clearly display the characteristics
CNC milling machine are shown in Table 2. In order to clearly display the characteristics and trends of
and trends of the material-drilling power, the measured material-drilling power values for the
the material-drilling power, the measured material-drilling power values for the researched machine
researched machine tools are also shown in Figure 7. It can be seen that the material-drilling power
tools are also shown in Figure 7. It can be seen that the material-drilling power of the XHK-714F CNC
of the XHK-714F CNC machining center is larger than the JTVM654 CNC milling machine under
machining center is larger than the JTVM654 CNC milling machine under the same combination of
the same combination of the drilling parameters. The main reason for this is that the rated power of
spindle motor (7.5 kW) of the XHK-714F CNC machining center is far greater than the rated power
Energies 2018, 11, 2013 9 of 16

the drilling parameters. The main reason for this is that the rated power of spindle motor (7.5 kW) of
the XHK-714F
Energies 2018,CNC machining
11, x FOR center is far greater than the rated power of spindle motor (4.0
PEER REVIEW 9 of kW)
16 of
the JTVM654 CNC milling machine. The material-drilling power is influenced by the additional loss
of which
power, spindleismotor
related(4.0with
kW)the
of rated
the JTVM654
power ofCNC
themilling
spindlemachine.
motor. The material-drilling power is
influenced by the additional loss power, which is related with the rated power of the spindle motor.

CNC machining center XHK-714F

600
CNC milling machine JTVM6540
Material-drilling power (W)

500

400

300

200

100

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Experiment No.

Figure 7. Comparison of the measured material-drilling power for the researched machine tools.
Figure 7. Comparison of the measured material-drilling power for the researched machine tools.
Table 2. Measured material-drilling power under different combinations of drilling parameters for
Tablethe MeasuredCNC
2. XHK-714F material-drilling power
machining center andunder different
JTVM654 combinations
CNC milling machine.of drilling parameters for the
XHK-714F CNC machining center and JTVM654 CNC milling machine.
Material-Drilling Material-Drilling
Drill Diameter Feed Rate Spindle Speed
No. Power Power
d (mm)
Drill Diameter fFeed
(mm/r)
Rate n (r/min)
Spindle Speed Material-Drilling Material-Drilling
No. Pmd 1 (W) 1 Pmd 2 (W) 2
d (mm) f (mm/r) n (r/min) Power Pmd (W) Power Pmd (W)
1 8 0.06 450 133.0 84.5
12 88 0.06
0.08 450
450 133.0
173.0 84.5
109.2
2 8 0.08 450 173.0 109.2
3 8 0.10 450 211.7 132.6
3 8 0.10 450 211.7 132.6
4 10 0.06 450 199.6 122.4
4 10 0.06 450 199.6 122.4
55 10
10 0.08
0.08 450
450 257.0
257.0 159.3
159.3
66 10
10 0.10
0.10 450
450 309.6
309.6 197.6
197.6
77 12
12 0.06
0.06 450
450 264.2
264.2 178.5
178.5
88 12
12 0.08
0.08 450
450 336.4
336.4 229.3
229.3
99 12
12 0.10
0.10 450
450 408.8
408.8 282.9
282.9
1010 88 0.06
0.06 550
550 152.8
152.8 102.7
102.7
1111 88 0.08
0.08 550
550 193.5
193.5 131.2
131.2
1212 88 0.10
0.10 550
550 238.2
238.2 159.9
159.9
13 10 0.06 550 230.6 150.0
13 10 0.06 550 230.6 150.0
14 10 0.08 550 292.6 190.3
14 10 0.08 550 292.6 190.3
15 10 0.10 550 350.7 235.8
1615 10
12 0.10
0.06 550
550 350.7
304.9 235.8
216.3
1716 12
12 0.06
0.08 550
550 304.9
384.6 216.3
275.8
1817 12
12 0.08
0.10 550
550 384.6
468.3 275.8
334.7
1918 128 0.10
0.06 550
650 468.3
166.5 334.7
118.6
2019 88 0.08
0.06 650
650 215.5
166.5 150.9
118.6
2120 88 0.10
0.08 650
650 261.4
215.5 183.3
150.9
2221 10
8 0.06
0.10 650
650 253.7
261.4 172.2
183.3
2322 10
10 0.08
0.06 650
650 319.6
253.7 220.3
172.2
24 10 0.10 650 388.1 272.8
23 10 0.08 650 319.6 220.3
25 12 0.06 650 340.2 248.7
2624 10
12 0.10
0.08 650
650 388.1
429.5 272.8
314.7
2725 12
12 0.06
0.10 650
650 340.2
529.7 248.7
385.9
26
1 Measured 12 0.08 650 429.5 314.7
material-drilling power for the XHK-714F CNC machining center. 2 Measured material-drilling power
27 12 0.10 650 529.7 385.9
for the JTVM654 CNC milling machine.
1 Measured material-drilling power for the XHK-714F CNC machining center. 2 Measured

material-drilling power for the JTVM654 CNC milling machine.

According to the above measured material-drilling power values, the curve fitting was carried
out according to Equations (6) and (10) with the Origin8.0® Software (OriginLab Corporation,
Northampton, MA, USA). The curve fitting results for material-drilling power of the XHK-714F
Energies 2018, 11, 2013 10 of 16

CNC machining center are shown in Table 3. In addition, the Analysis Of Variance (ANOVA) for the
material-drilling power of the XHK-714F CNC machining center is shown in Table 4.

Table 3. Curve fitting results for material-drilling power of the XHK-714F CNC machining center.

Model Coefficients Value Standard Error t-Value Prob > |t| Statistics
λ D1 0.095 0.021 4.530 1.371 × 10−4 R-Square(COD)
Model A 1 α D1 1.675 0.072 23.153 0 0.974
5.462 ×
β D1 0.856 0.055 15.479
10−14
λ D2 0.866 0.107 8.095 3.499 × 10− 8 R-Square(COD)
α D2 1.673 0.018 94.531 0 0.998
Model B 2 β D2 0.856 0.014 63.256 0
γD2 0.652 0.017 37.493 0
1 Empirical model with the equation Pmd = λ D1 · dαD1 · f β D1 · n. 2 Improved model with the equation
Pmd = λ D2 · dαD2 · f β D2 · nγD2 .

Table 4. ANOVA for material-drilling power of the XHK-714F CNC machining center.

Model Items DF Sum of Squares Mean Square F Value Prob > F

Regression 3 2.517 × 106 839,115.840 2951.245 0
Residual 24 6823.826 284.326
Model A 1 Uncorrected
27 2.524 × 106
Total
Corrected
26 262,952.539
Total
Regression 4 2.524 × 106 630,944.704 36,969.728 0
Residual 23 392.530 17.067
Model B 2 Uncorrected
27 2.524 × 106
Total
Corrected
26 262,952.539
Total
1 Empirical model with the equation Pmd = λ D1 · dαD1 · f β D1 · n. 2 Improved model with the equation
Pmd = λ D2 · dαD2 · f β D2 · nγD2 .

According to the fitting results of Table 3, the coefficients and exponents in the traditional empirical
model of material-drilling power are as follows: λ D1 = 0.095, α D1 = 1.675, and β D1 = 0.856. Therefore,
the traditional empirical model of material-drilling power of the CNC machining center XHK-714F
can be expressed as:
Pmd (XHK − 714F) = 0.095 d1.675 × f 0.856 × n (11)

Similarly, the coefficients and exponents in the improved model of material-drilling power are
obtained according to Table 3. The values are shown as follows: λ D2 = 0.866, α D2 = 1.673, β D2 = 0.856,
and γD2 = 0.652. Consequently, the improved material-drilling power model of the CNC machining
center XHK-714F can be written as:

Pmd (XHK − 714F) = 0.866 d1.673 × f 0.856 × n0.652 (12)

According to the ANOVA table for material-drilling power of the CNC machining center
XHK-714F (Table 4), the P value for the model A and model B are both very small (Prob = 0 < 0.05, 95%
confidence level), which indicates the strong correlation between Pmd (material-drilling power) and
the drilling parameter d (cutter diameter), f (feed rate) and n (spindle speed). In addition, the R-Square
value can be obtained according to Table 3, R-Square = 0.974 for the model A and R-Square = 0.998 for
the model B. The closer the R-Square value is to 1, the better the fitting result is. Therefore, the model B
(improved material-drilling power model) could describe the material-drilling power under various
Energies 2018, 11, 2013 11 of 16

combinations of cutter diameter, feed rate and spindle speed better than the model A (traditional
empirical material-drilling power model).
In order to further show the validity of the improved material-drilling power model,
the experimental data obtained on the JTVM654 CNC milling machine were analyzed. Similarly,
the curve fitting was conducted according to Equations (6) and (10) with the Origin8.0® Software.
The curve fitting results for material-drilling power of the JTVM654 CNC milling machine were shown
in Table 5. In addition, the Analysis Of Variance (ANOVA) for material-drilling power of the JTVM654
CNC milling machine is shown in Table 6.

Table 5. Curve fitting results for material-drilling power of the JTVM6540 CNC milling machine.

Model Coefficients Value Standard Error t-Value Prob > |t| Statistics
3.211 × R-Square
λ D1 0.045 0.004 10.220
1
10− 10 (COD)
Model A α D1 1.860 0.032 57.680 0 0.996
β D1 0.881 0.024 36.491 0
R-Square
λ D2 0.103 0.013 7.818 6.349 × 10− 8
(COD)
Model B 2 α D2 1.860 0.019 100.424 0 0.999
β D2 0.881 0.014 63.542 0
γD2 0.870 0.018 48.645 0
1 Empirical model with the equation Pmd = λ D1 · dαD1 · f β D1 · n. 2 Improved model with the equation
Pmd = λ D2 · dαD2 · f β D2 · nγD2 .

Table 6. ANOVA for material-drilling power of the JTVM6540 CNC milling machine.

Model Items DF Sum of Squares Mean Square F Value Prob > F

Regression 3 1.215 ×106 405,086.248 15,596.363 0
Residual 24 623.355 25.973
Model A 1 Uncorrected
27 1.216 × 106
Total
Corrected
26 151,650.362
Total
Regression 4 1.216 × 106 303,921.230 35,451.033 0
Residual 23 197.179 8.573
Model B 2 Uncorrected
27 1.216 × 106
Total
Corrected
26 151,650.362
Total
1 Empirical model with the equation Pmd = λ D1 · dαD1 · f β D1 · n. 2 Improved model with the equation Pmd =
λ D2 · dαD2 · f β D2 · nγD2 .

According to the fitting results of Table 5, the coefficients and exponents in the traditional empirical
model of material-drilling power are as follows: λ D1 = 0.045, α D1 = 1.860, and β D1 = 0.881. Therefore,
the traditional empirical model of material-drilling power of the JTVM6540 CNC milling machine can
be expressed as:
Pmd (JTVM6540) = 0.045 d1.860 × f 0.881 × n (13)

Similarly, the coefficients and exponents in the improved model of material-drilling power are
obtained according to Table 5. The values are shown as follows: λ D2 = 0.103, α D2 = 1.860, β D2 = 0.881,
and γD2 = 0.870. Consequently, the improved material-drilling power model of the JTVM6540 CNC
milling machine can be written as:

Pmd (JTVM6540) = 0.103 d1.860 × f 0.881 × n0.870 (14)

Energies 2018, 11, 2013 12 of 16

According to the ANOVA table for material-drilling power of the JTVM654 CNC milling machine
(Table 6), the P value for the model A and model B are both very small (Prob = 0 < 0.05, 95% confidence
level), which indicates the strong correlation between Pmd (material-drilling power) and the drilling
parameter d (cutter diameter), f (feed rate) and n (spindle speed). In addition, the R-Square value can
be obtained according to Table 5, R-Square = 0.996 for the model A and R-Square = 0.999 for the model
B. The closer the R-Square value is to 1, the better the fitting result is. Therefore, for the JTVM654 CNC
milling machine the model B (improved material-drilling power model) is also better than the model A
(traditional empirical material-drilling power model) for describing the material-drilling power under
various combinations of cutter diameter, feed rate and spindle speed.
In order to show the effectiveness of the improved material-drilling power model, four random
tests were selected and the detailed drilling parameters of the four tests are listed in Table 7. In
order to make the experiments more scientific and more credible, the four test experiments were
carried out on both the XHK-714F CNC machining center and the JTVM6540 CNC milling machine.
The material-drilling power during drilling process of the researched machine tool were measured by
the power-energy acquisition system shown in Figure 6. The predicted material-drilling power values
were obtained with both the traditional empirical model and the improved power model in this paper,
as shown in Table 7.

Table 7. The accuracy of the developed material-drilling power models of four test cases.

CNC Machining Center XHK-714F CNC Milling Machine JTVM6540

Items
Test 1 Test 2 Test 3 Test 4 Test 1 Test 2 Test 3 Test 4
Drill diameter (mm) 12 10 10 8 12 10 10 8
Feed rate (mm/r) 0.07 0.08 0.07 0.09 0.07 0.08 0.07 0.09
Spindle speed (r/min) 460 580 540 640 460 580 540 640
Measured power (W) 319.8 298.1 256.8 236.5 213.8 200.8 170.6 166.4
Predicted P with model A 1 (W) 288.1 300.1 249.2 252.0 202.2 204.3 169.1 165.1
Predicted P with model B 2 (W) 309.4 297.4 253.2 241.5 208.6 204.5 170.8 163.2
Accuracy of model A 90.1% 99.3% 97.0% 93.4% 94.6% 98.3% 99.1% 99.2%
Accuracy of model B 96.7% 99.8% 98.6% 97.9% 97.6% 98.2% 99.9% 98.1%
1 Empirical model with the equation Pmd = λ D1 · dαD1 · f β D1 · n. 2 Improved model with the equation
Pmd = λ D2 · dαD2 · f β D2 · nγD2 .

The comparison of accuracy of the traditional empirical model (model A) and the improved power
model in this paper (model B) for the researched machine tools (XHK-714F CNC machining center
and JTVM6540 CNC milling machine) are shown in Figures 8 and 9. It can be seen that the improved
material-drilling power model can improve the prediction accuracy of the material-drilling power.
As shown in Figure 8, the prediction accuracies of Test 1–Test 4 are 96.7%, 99.8%, 98.6%, and 97.9%
for the XHK-714F CNC machining center. The prediction accuracies are improved by 6.6%, 0.5%,
1.6%, and 4.5% compared with the traditional empirical model of material-drilling power. Moreover,
the average accuracy of the improved material-drilling power model is up to 98.3%, which is improved
by 3.3% compared with the traditional empirical model.
Energies 2018, 11, 2013 13 of 16
Energies 2018, 11, x FOR PEER REVIEW 13 of 16
Energies 2018, 11, x FOR PEER REVIEW 13 of 16

Model A Model B
Model A Model B
96.7% 99.8% 98.6% 97.9% 98.3%
100% 99.8% 98.6% 97.9% 98.3%
96.7%
100% 99.3% 97.0% 93.4% 95.0%
80% 90.1% 99.3% 97.0% 93.4% 95.0%
80% 90.1%
(%)(%)

60%
Accuracy

60%
Accuracy

40%
40%
20%
20%
0%
0% Test 1 Test 2 Test 3 Test 4 Average
Test 1 Test 2 Test 3 Test 4 Average
CNC machining center XHK-714F
CNC machining center XHK-714F
Figure 8. Comparison of accuracy of model A and B for XHK-714F CNC machining center.
Figure Comparison
8. 8.
Figure Comparisonofofaccuracy
accuracyof
ofmodels
model AAand
andBBfor
forXHK-714F
XHK-714FCNC
CNC machining
machining center.
center.

Model A Model B
Model A Model B
97.6% 98.2% 99.9% 98.1% 98.5%
100% 98.2% 99.9% 98.1% 98.5%
97.6%
100% 98.3% 99.1% 99.2% 97.8%
94.6%
80% 98.3% 99.1% 99.2% 97.8%
94.6%
(%)(%)

80%
60%
Accuracy

60%
Accuracy

40%
40%
20%
20%
0%
0% Test 1 Test 2 Test 3 Test 4 Average
Test 1 Test 2milling machine
CNC Test 3JTVM6540 Test 4 Average
CNC milling machine JTVM6540
Figure 9. Comparison of accuracy of model A and B for JTVM6540 CNC milling machine.
Figure 9. Comparison of accuracy of model A and B for JTVM6540 CNC milling machine.
Figure 9. Comparison of accuracy of models A and B for JTVM6540 CNC milling machine.
As shown in Figure 9, the improved material-drilling power model (model B) can improve the
As
prediction shown in Figure
accuracy of the 9, material-drilling
the improved material-drilling
power compared power with model (model B) empirical
the traditional can improve modelthe
As shown
prediction in Figure
accuracy of 9, the
the improved material-drilling
material-drilling power compared powerwith model
the (model B)
traditional can improve
empirical model the
of the material-drilling power (model B). It can be seen that the average accuracy of the improved
prediction
of accuracy of the
the material-drilling material-drilling It power compared with the traditional ofempirical model
material-drilling powerpower model(model
is up B). to 98.5%,can be seen
which that the
is improved average by accuracy
0.7% compared the improved
with the
of material-drilling
the material-drilling power power
model (model
is up B).
to It can be
98.5%, seen is
which that the average
improved by accuracy
0.7% of thewith
compared improved
the
traditional empirical model. The results show that the prediction accuracy of the improved
material-drilling
traditional
material-drilling power
empirical model
powermodel. is
model The up to 98.5%,
results in
established which
show is improved
that the
this paper by 0.7% compared
prediction accuracy
is significantly with
improved,ofgenerally the traditional
the improved higher
empirical model.
material-drilling The
power results
model show that
established the in prediction
this paper accuracy
is of
significantly
than 96% for all the test experiments of the researched machine tools (XHK-714F CNC machining the improved
improved, material-drilling
generally higher
than
power
center 96%
andfor
model all the test
established
JTVM6540 CNCinexperiments
this paper
milling isofsignificantly
machine).the researched machinegenerally
improved, tools (XHK-714F CNC96%
higher than machining
for all the
testcenter and
experiments JTVM6540
of the CNC milling
researched machine).
machine tools (XHK-714F CNC
It can be seen that although the accuracy of the traditional empirical model is not low, it canmachining center and JTVM6540
CNC It can
milling
further be seen that
machine).
be improved although
by the improved the accuracy of the traditional
material-drilling power model empirical
in thismodel
paper. isThenotmain
low,reason
it can
further
is It canbe
that beimproved
the seen
exponent byofthe
that althoughtheimproved
spindle material-drilling
the accuracy
speed of theassumed
was power
traditional model
toempirical
be a fixed in model
this paper.
value is notThe
low,
(fixed main
toit1)can reason
infurther
the
is that
be traditionalthe
improved by exponent
the improved
empirical of the spindle speed
model.material-drilling was
However, this assumption assumed
power modelisinnot to be a
thisveryfixed
paper. value
The main
consistent (fixed to
reason
with 1)
the is in the
that the
exiting
traditional
researchofresult
exponent empirical
the [51] and
spindle model.
speed our However,
was previous
assumed this to assumption
experimental
be a fixedresult is not
value veryto consistent
showed
(fixed in in
1) Figure with the empirical
5. Actually,
the traditional exiting
the
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influence
model. result
of thethis
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drilling our previous
assumption is not(drillexperimental
very diameter
consistent d,result
feed the
with showed
rate f, and
exiting inresearch
Figure speed
spindle 5. Actually,
result n) on
[51] andthe
theour
influence of the power
material-drilling drillingare parameters
different. (drill
The diameterinfluence
different d, feed rateof f, and
each spindle
drilling speed n)
parameter has onbeen
the
previous experimental result showed in Figure 5. Actually, the influence of the drilling parameters (drill
material-drilling
reflected power are different. The different influence of each drilling parameter hasinbeen
diameter d, in
feedtherate
improved material-drilling
f, and spindle speed n) on power model. The exponent
the material-drilling power of are
the different.
spindle speed the
The different
reflected
improved in the
model improved material-drilling
is not parameter
a fixed value. power model. The exponent of the spindle speed in the
influence of each drilling has Its
been value is affected
reflected in theby the cutting
improved tool, workpiece
material-drilling material,
power model.
improved
and machine modeltool. isThat
not is a to
fixed
say, value.
the Its value
value may is affected
be different by the cutting
under different tool, workpieceofmaterial,
combinations cutting
The exponent of the spindle speed in the improved model is not a fixed value. Its value is affected
and
tools, machine
workpiece tool.materials,
That is toand say,machine
the valuetools.may It becan
different
be drawn under different
that the combinations
improved of cutting
material-drilling
bytools,
the cutting
workpiece
tool,materials,
workpiece and
material,
machine
andtools.
machine
It can
tool.
be drawn
Thatthatis tothesay, the valuematerial-drilling
improved
may be different
power model is more reasonable and scientific compared with the traditional empirical model. The
under
power different
model combinations
is morecan of cutting
reasonable and to tools, workpiece
scientific materials, and machine tools. It model.
can be drawn
prediction accuracy be expected becomecomparedbetter with with thethe traditional
improved empirical
material-drilling powerThe
that the improved
prediction accuracy material-drilling
can be expected power
to model
become is more
better with reasonable
the improved and scientific compared
material-drilling power with
model. The experimental results also verify the above statement.
themodel.
traditional empirical model. The prediction
The experimental results also verify the above statement. accuracy can be expected to become better with the
improved material-drilling power model. The experimental results also verify the above statement.
Energies 2018, 11, 2013 14 of 16

5. Conclusions
Drilling process is some of the most widely used machining processes in the manufacturing
industry. Establishing the accurate power model of the drilling process plays a significant role in
manufacturing process energy modeling and energy savings. Material-drilling power is an important
part of total drilling power, which is insufficiently researched. In this paper, the composition of
the material-drilling power is studied firstly. Then, an improved material-drilling power model is
established. Finally, experimental studies were carried out on a XHK-714F CNC machining center and
JTVM6540 CNC milling machine. The results showed that the prediction accuracy of the improved
material-drilling power model established in this paper is significantly improved, generally higher than
96% for all the test experiments. The average prediction accuracies of the improved material-drilling
power are 98.3% and 98.5% for the XHK-714F CNC machining center and JTVM6540 CNC milling
machine, respectively. Moreover, the prediction accuracy with the proposed model can be increased
compared with the traditional empirical model, improvement of 3.3% and 0.7% can be achieved
for the XHK-714F CNC machining center and JTVM6540 CNC milling machine. The power model
proposed in this paper can provide a good foundation for energy modeling and optimization of
drilling processes. Moreover, the establishment of a material-drilling power model can improve the
transparency of energy consumption and help us to better understand the energy characteristics during
drilling processes.
The differences and trends of the coefficients in the proposed model under different combinations
of machine tools, cutting tools, and workpiece materials will be studied in our future research.
Moreover, the material-drilling power is a crucial part of the total drilling power. With the proposed
material-drilling power model, further research will be carried out to analyze and establish a prediction
model of total drilling power, and then the energy optimization model of drilling processes will
be researched.

Author Contributions: Q.Y. (Qinghe Yuan) and W.C. proposed the paper structure, S.J., J.L. and Z.Z. designed
and performed the experiments. C.L. revised and improved the paper. S.J. and Q.Y. (Qingwen Yuan) conceived
the paper, analyzed the data and wrote the paper.
Funding: This research was supported by the National Natural Science Foundation of China (Grant No. 71701113),
Shandong Provincial Natural Science Foundation, China (Grant No. ZR2016GQ11, ZR2016EEP02), Project of
Shandong Province Higher Educational Science and Technology Program (Grant No. J17KA167), and supported
by SDUST Research Fund (Grant No. 2018YQJH103).
Acknowledgments: The authors sincerely thank editors and anonymous reviewers for their helpful suggestions
on the quality improvement of our paper.
Conflicts of Interest: The authors declare no conflict of interest.

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