Greenhouse gas emissions are caused by human activities, one of which is the manufacturing process, which is the main driver of global warming. The machining process is a common practice in sectors such as aerospace and automotive. Based on the latter, this research focuses on understanding and testing an alternative way to make an economically sustainable machining process. This study reports on the performance of tool life analysis under dry settings, and the cutting speed calculation considers machining and tooling costs. Developing a design of the experiment established the power demand equation, which is part of the energy model presented in this research, and it also helps to understand the carbon dioxide emissions to the environment before starting the milling process. Based on the results, the tool life evaluation shows the longest working time under good tool conditions with a measured surface roughness of less than 0.6 μm. The energy model shows the alternative to improve energy consumption and CO₂ emissions by 0.11 kWh and 0.055 kg CO_2, respectively, which is essential to understand the challenge of reducing the manufacturing footprint.

This paper reports on a comparative study realized to contrast between the part code generated by two different CAM systems and one part program generated by the authors. This comparison addresses in particular tool path, but also includes number of lines, cycle time and energy consumption. The comparison is carried out through a case study: a mechanical component was designed so as to produce a number of CNC part programs generated with two different CAM systems; one more program was directly programmed by the authors in the machine tool's controller. Different sample parts were produced using the same machine tool, tooling and process parameters; and measurements of energy consumption and cycle time were gathered. The results show differences between the tool paths generated by each approach and are used by the authors to further define strategies to produce trajectories that could reduce cycle time and energy consumption

Very commonly, a mechanical workpiece manufactured industrially includes more than one machining operation. Even more, it is a common activity of programmers, who make a decision in this regard every time a milling and drilling operation is performed. This research is focused on better understanding the power behavior for face milling and drilling manufacturing operations, and the methodology followed was the design of experiments (DOEs) with the cutting parameters set in combination with toolpath evaluation available in commercial software, having as main goal to get a predictive power equation validated in two ways, linear or nonlinear, and understanding the energy consumption and the quality surface in face milling and final diameter in drilling. The results show that it is possible to find difference in a power demand of 1.52 kW to 3.9 kW in the same workpiece, depending on the operations (face milling or drilling), cutting parameters, and toolpath chosen. Additionally, the equations modelled showed acceptable values to predict the power, with p values higher than 0.05 which is the significance level for the nonlinear and linear equations with an R square predictive of 98.36. Some conclusions established that optimization of the cutting parameters combined with toolpath strategies can represent an energy consumption optimization higher than 0.21% and the importance to try to find an energy consumption balance when a workpiece has different milling operations.

Tool selection is relevant because a wide variety of materials exhibit different machinability behaviors. Tool life during manufacturing is commonly associated with productivity. Insert developers have been using coatings on cutting tools to enhance their performance, with chemical vapor deposition (CVD) and physical vapor deposition (PVD) being the two most used techniques. This study analyzed the cutting tool wear mechanism by machining AISI D2 steel using two different inserts of TiAlN/TiN PVD and TiCN/Al₂O₃ CVD as layers deposited on a carbide substrate. The two inserts were tested at three different cutting speeds, namely, low, medium, and high; these values were below the data suggested by the supplier catalog. The flank wear and rake face were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectrometry (EDX). The adhesion material, edge deformation, and abrasion were the main wear mechanisms before catastrophic damage occurred at the three different cutting speeds in the PVD cutting tool. Nevertheless, increasing the cutting speed reduced the tool life from 84% to 61% at high values compared to the medium values of PVD and CVD, respectively, where the medium value resulted in a balance between the material removal rate and tool life. The wear mechanism of the CVD tool was BUE and chipping; nevertheless, its craters were larger than those of the PVD. Compared to those configured for PVD, the CVD insert demonstrated the ability to machine D2 steel at twice the cutting speed with a workpiece surface roughness of 0.3 µm, in contrast to a variation of 0.6 to 0.15 µm with the PVD tool.

The obtention of luminescent SiO_xC_y:H thin films deposited by the HW-CVD technique is reported here. We study the effect of different monomethyl-silane (MMS) flow rates on the films properties. An increase in the emission bandwidth and a red-shift was observed when the MMS flow increased. The luminescence was related to optical transitions in band tail states and with less contribution from quantum confinement effects. After, the films were annealed at 750 °C in nitrogen. The annealed film deposited at the highest MMS flow showed an emission spectrum like the as-deposited film, suggesting the same emission mechanisms. By contrast, the annealed film deposited at the lowest MMS flow showed two emission bands. These bands are due to the activation of radiative defects related to oxygen-deficient centers. MOS-like structures were fabricated as electroluminescent devices using the annealed films. Only the structure of the film with the highest carbon content showed light emission in a broad band in the visible spectrum region in forward bias, with a maximum centered close to 850 nm. The light emission mechanism was related to electron thermalization in the band tail states and a direct hole injection into deep states. The trap-assisted tunneling, Poole–Frenkel emissions and Fowler–Nordheim tunneling were proposed as the charge transport mechanism.