The specific energy consumption of machine tools and surface roughness are important indicators for evaluating energy consumption and surface quality in processing. Accurate prediction of them is the basis for realizing processing optimization. Although tool wear is inevitable, the effect of tool wear was seldom considered in the previous prediction models for specific energy consumption of machine tools and surface roughness. In this paper, the prediction models for specific energy consumption of machine tools and surface roughness considering tool wear evolution were developed. The cutting depth, feed rate, spindle speed, and tool flank wear were featured as input variables, and the orthogonal experimental results were used as training points to establish the prediction models based on support vector regression (SVR) algorithm. The proposed models were verified with wet turning AISI 1045 steel experiments. The experimental results indicated that the improved models based on cutting parameters and tool wear have higher prediction accuracy than the prediction models only considering cutting parameters. As such, the proposed models can be significant supplements to the existing specific energy consumption of machine tools and surface roughness modeling, and may provide useful guides on the formulation of cutting parameters.

The accurate energy consumption characteristics evaluation in machining is helpful to optimize processing scheme to realize low carbon manufacturing. The energy consumption characteristics evaluation method in turning is researched, which includes energy efficiency calculation and energy consumption prediction. First, the simple and accurate energy efficiency computational model in turning is put forward. Second, the energy consumption prediction empirical model and the back-propagation neural network prediction model are developed respectively. Finally, the power signal measurement system is built on computer numerical controlled lathe, and the proposed energy efficiency computational model and the energy consumption prediction methods are verified in the 45# steel semi-finish turning with hard alloy cutting tools. The results show that the proposed methods can effectively evaluate the energy consumption characteristics in turning, which can help to select the high energy efficiency processing program on the basis of ensuring processing quality.

The global energy crisis and climate warming are becoming more and more serious. How to reduce energy consumption and environmental pollution to achieve low-carbon manufacturing is an urgent problem to solve. Tool wear leads to the increase of cutting force and cutting power of machine tools obviously. So the influence of tool wear on energy consumption of machine tools cannot be ignored. Firstly, the power of CNC machine tool in cutting stage is divided into standby power, cutting material power and spindle no-load power in the paper. Then, the specific energy consumption prediction model of CNC machine tools based on tool wear is developed. Furthermore, the proposed model is verified with dry milling 45# steel experiments, and the prediction accuracy can reach 98.2% according to material removal rate, spindle speed and tool wear. Finally, the influence of processing parameters and tool wear on specific energy consumption of machine tools is studied. The research is helpful to optimize the processing parameters and tool conditions to reduce the energy consumption of machine tools.