Feed drive model for machine tool energy consumption simulation

This paper presents a simulation-based framework for estimating the energy consumption of a machine tool at the component level. A virtual machine tool simulator is designed focusing on accurately estimating the energy consumption of the feed drives and spindle motor that account for a large part of the total energy consumption. Mechanical and electrical energy consumption of feed drive components are analyzed theoretically and modeled. The experimental setup of a machine tool feed drive system is constructed for verifying the feed drive model. Simplified spindle model, cutting dynamics, and auxiliary unit model are contained in the machine tool simulator for profiling of energy consumption of machine tool components during milling processes. Using the proposed simulation specific energy consumption (SEC) change with respect to different feed rates and spindle motor selection are simulated to analyze the machine tool energy consumption.