Eficiência energética rumo à usinagem sustentável: comparação entre trajetórias linear e senoidal no fresamento tangencial da liga ti-6al-4v

Abstract

Sustainability is one of the fundamental pillars for industrial development and the maintenance of quality of life in society. The environment constantly faces significant challenges, reflecting the complex interaction between human activities and the ecosystems that sustain them. The planet is experiencing a critical moment in which environmental degradation has reached alarming levels, affecting biodiversity, climate, and the quality of air, water, and soil, thereby compromising the health and well-being of global populations. In the industrial context, sustainable manufacturing, which aims to minimize negative environmental impacts while maintaining economic viability, has become a strategic priority. Electrical energy consumption in machine tools is a key concern, particularly in the metalworking industry, where the search for solutions to reduce this impact has become increasingly relevant. Energy efficiency and tool wear are critical factors in CNC machines' machining processes. The selected milling path can directly impact energy consumption and tool durability, influencing operational efficiency and production costs. However, a detailed understanding of the impact of linear and sinusoidal tool paths on active power consumption during tangential milling still presents gaps. This study investigates the influence of linear and sinusoidal tool paths and cutting parameters on mean active power, energy consumption, energy efficiency, and 𝐶𝑂2 emissions in the tangential milling of Ti-6Al-4V alloy. The experiments were conducted on a CNC machine, with data acquisition from both the general power output and the spindle, while varying the cutting speed (60 and 85 m/min), depth of cut (0.5 and 1.0 mm), and feed per tooth (0.11 and 0.16 mm/tooth). The results indicate that the depth of cut is the primary influencing factor, significantly impacting mean active power and energy consumption at both the general output of the CNC machine and the spindle. During milling with the sinusoidal tool path, the mean active power at the spindle was 4.6% lower compared to the linear tool path, with a 14% reduction in energy consumption, a 7.8% increase in energy efficiency, and a 26% reduction in 𝐶𝑂2 emissions during the selected effective machining period. The results suggest that the sinusoidal tool path is a sustainable alternative for machining processes involving high material removal rates. These findings reinforce the potential of the sinusoidal tool path, highlighting that the tool path selection and proper parameterization of machining processes are essential for improving energy efficiency in the metalworking industry, advancing toward sustainable manufacturing.