Skip to main content
SpringerLink
Log in

Energy Consumption Model for Additive-Subtractive Manufacturing Processes with Case Study

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing-Green Technology Aims and scope Submit manuscript

Abstract

There has been a growing trend in industry towards the development of integrated manufacturing centers that combine several manufacturing processes, such as the mill-turn center. As additive manufacturing becomes a more widely adopted technology, combining additive with subtractive manufacturing in one machine is a logical evolution to provide the benefits of final parts made from raw materials with the dimensional tolerance and surface finish expected in many applications. An energy consumption model was created that accounted for the energy consumption during primary metal production, deposition, and machining phases of wire-based and powder-based additive-subtractive manufacturing processes. This model was applied to a case study where the energy consumption to produce sub-sized, sheet type, and plate type (size) tensile bars was calculated. It was found that the wire-based process consumed less energy during deposition, whereas powder-based was less energy consumptive during primary metal production and machining. The findings suggest that given the present understanding of the respective technologies’ capabilities, the desired final net shape will dictate the preferred manufacturing process with respect to energy consumption considerations.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Abbreviations

CNC:

Computer numerical control

cp :

Specific heat

η :

Energy conversion efficiency

GMAW:

Gas metal arc welding

LAMP:

Laser aided manufacturing process

LENS:

Laser engineered net shaping

MIG:

Metal inert gas

MRR:

Material removal rate

Nd:YAG:

Neodymium-doped yttrium aluminum garnet

PMP:

Primary metal production

SEC:

Specific energy consumption

References

  1. US Energy Information Administration, “Manufacturing Energy Consumption Survey (MECS),” https://doi.org/www.eia.gov/consumption/manufacturing/briefs/ (Accessed 1 AUG 2018)

  2. Yoon, H.-S., Lee, J.-Y., Kim, H.-S., Kim, M.-S., Kim, E.-S., et al., “A Comparison of Energy Consumption in Bulk Forming, Subtractive, and Additive Processes: Review and Case Study,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 1, No. 3, pp. 261–279, 2014.

    Article  Google Scholar 

  3. Conti, J. J., Holtberg, P. D., Beamon, J. A., Schaal, A. M., Ayoub, J., et al., “Annual Energy Outlook 2014,” US Energy Information Administration, 2014.

    Google Scholar 

  4. Fatih, B., “World Energy Outlook 2015,” Organisation for Economic Co-Operation and Development (OECD): Paris, France, 2015.

    Google Scholar 

  5. Dornfeld, D. and Wright, P., “‘Technology Wedges’ for Implementing Green Manufacturing,” Trans NAMRI/SME, Vol. 35, No. 1, 2007.

    Google Scholar 

  6. Duflou, J. R., Kellens, K., Guo, Y., and Dewulf, W., “Critical Comparison of Methods to Determine the Energy Input for Discrete Manufacturing Processes,” CIRP Annals-Manufacturing Technology, Vol. 61, No. 1, pp. 63–66, 2012.

    Article  Google Scholar 

  7. Fang, K., Uhan, N., Zhao, F., and Sutherland, J. W., “A New Approach to Scheduling in Manufacturing for Power Consumption and Carbon Footprint Reduction,” Journal of Manufacturing Systems, Vol. 30, No. 4, pp. 234–240, 2011.

    Article  Google Scholar 

  8. Linke, B. S., Corman, G. J., Dornfeld, D. A., and Tönissen, S., “Sustainability Indicators for Discrete Manufacturing Processes Applied to Grinding Technology,” Journal of Manufacturing Systems, Vol. 32, No. 4, pp. 556–563, 2013.

    Article  Google Scholar 

  9. Salonitis, K. and Ball, P. D., “Energy Efficient Manufacturing from Machine Tools to Manufacturing Systems,” Procedia CIRP, Vol. 7, pp. 634–639, 2013.

    Article  Google Scholar 

  10. Schmidt, C., Li, W., Thiede, S., Kara, S., and Herrmann, C., “A Methodology for Customized Prediction of Energy Consumption in Manufacturing Industries,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 2, No. 2, pp. 163–172, 2015.

    Article  Google Scholar 

  11. Frazier, W. E., “Metal Additive Manufacturing: A Review,” Journal of Materials Engineering and Performance, Vol. 23, No. 6, pp. 1917–1928, 2014.

    Article  Google Scholar 

  12. Huang, S. H., Liu, P., Mokasdar, A., and Hou, L., “Additive Manufacturing and its Societal Impact: A Literature Review,” The International Journal of Advanced Manufacturing Technology, Vol. 67, Nos. 5–8, pp. 1191–1203, 2013.

    Article  Google Scholar 

  13. Chu, W.-S., Kim, C.-S., Lee, H.-T., Choi, J.-O., Park, J.-I., et al., “Hybrid Manufacturing in Micro/Nano Scale: A Review,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 1, No. 1, pp. 75–92, 2014.

    Article  Google Scholar 

  14. Flynn, J. M., Shokrani, A., Newman, S. T., and Dhokia, V., “Hybrid Additive and Subtractive Machine Tools-Research and Industrial Developments,” International Journal of Machine Tools and Manufacture, Vol. 101, pp. 79–101, 2016.

    Article  Google Scholar 

  15. Kou, S., “Welding Metallurgy,” New Jersey, 2nd Ed., pp. 431–446, 2003.

    Google Scholar 

  16. Song, Y.-A., Park, S., Choi, D., and Jee, H., “3D Welding and Milling: Part I-A Direct Approach for Freeform Fabrication of Metallic Prototypes,” International Journal of Machine Tools and Manufacture, Vol. 45, No. 9, pp. 1057–1062, 2005.

    Article  Google Scholar 

  17. Karunakaran, K., Suryakumar, S., Pushpa, V., and Akula, S., “Low Cost Integration of Additive and Subtractive Processes for Hybrid Layered Manufacturing,” Robotics and Computer-Integrated Manufacturing, Vol. 26, No. 5, pp. 490–499, 2010.

    Article  Google Scholar 

  18. Liou, F., Slattery, K., Kinsella, M., Newkirk, J., Chou, H.-N., et al., “Applications of a Hybrid Manufacturing Process for Fabrication of Metallic Structures,” Rapid Prototyping Journal, Vol. 13, No. 4, pp. 236–244, 2007.

    Article  Google Scholar 

  19. Diaz, N., Redelsheimer, E., and Dornfeld, D., “Energy Consumption Characterization and Reduction Strategies for Milling Machine Tool Use,” in: Glocalized Solutions for Sustainability in Manufacturing, Herrmann, C. and Hesselbach, J., (Eds.,) Springer, pp. 263–267, 2011.

    Chapter  Google Scholar 

  20. He, Y., Liu, F., Wu, T., Zhong, F., and Peng, B., “Analysis and Estimation of Energy Consumption for Numerical Control Machining,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 226, No. 2, pp. 255–266, 2012.

    Article  Google Scholar 

  21. Kara, S. and Li, W., “Unit Process Energy Consumption Models for Material Removal Processes,” CIRP Annals-Manufacturing Technology, Vol. 60, No. 1, pp. 37–40, 2011.

    Article  Google Scholar 

  22. Li, L., Yan, J., and Xing, Z., “Energy Requirements Evaluation of Milling Machines Based on Thermal Equilibrium and Empirical Modelling,” Journal of Cleaner Production, Vol. 52, pp. 113–121, 2013.

    Article  Google Scholar 

  23. Campatelli, G., Scippa, A., Lorenzini, L., and Sato, R., “Optimal Workpiece Orientation to Reduce the Energy Consumption of a Milling Process,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 2, No. 1, pp. 5–13, 2015.

    Article  Google Scholar 

  24. Mativenga, P. and Rajemi, M., “Calculation of Optimum Cutting Parameters Based on Minimum Energy Footprint,” CIRP Annals-Manufacturing Technology, Vol. 60, No. 1, pp. 149–152, 2011.

    Article  Google Scholar 

  25. Neugebauer, R., Schubert, A., Reichmann, B., and Dix, M., “Influence Exerted by Tool Properties on the Energy Efficiency during Drilling and Turning Operations,” CIRP Journal of Manufacturing Science and Technology, Vol. 4, No. 2, pp. 161–169, 2011.

    Article  Google Scholar 

  26. Le Bourhis, F., Kerbrat, O., Hascoët, J.-Y., and Mognol, P., “Sustainable Manufacturing: Evaluation and Modeling of Environmental Impacts in Additive Manufacturing,” The International Journal of Advanced Manufacturing Technology, Vol. 69, Nos. 9–12, pp. 1927–1939, 2013.

    Article  Google Scholar 

  27. Faludi, J., Bayley, C., Bhogal, S., and Iribarne, M., “Comparing Environmental Impacts of Additive Manufacturing vs. Traditional Machining via Life-Cycle Assessment,” Rapid Prototyping Journal, Vol. 21, No. 1, pp. 14–33, 2015.

    Article  Google Scholar 

  28. Clemon, L., Sudradjat, A., Jaquez, M., Krishna, A., Rammah, M., et al., “Precision and Energy Usage for Additive Manufacturing,” Proc. of ASME International Mechanical Engineering Congress and Exposition, Paper No. V02AT02A015, 2013.

    Google Scholar 

  29. Baumers, M., Tuck, C., Wildman, R., Ashcroft, I., and Hague, R., “Energy Inputs to Additive Manufacturing: Does Capacity Utilization Matter,” Eos, Vol. 1000, No. 270, pp. 30–40, 2011.

    Google Scholar 

  30. Kellens, K., Dewulf, W., Deprez, W., Yasa, E., and Duflou, J., “Environmental Analysis of SLM and SLS Manufacturing Processes,” Proc. of LCE Conference, pp. 423–428, 2010.

    Google Scholar 

  31. Unocic, R. and DuPont, J., “Process Efficiency Measurements in the Laser Engineered Net Shaping Process,” Metallurgical and Materials Transactions B, Vol. 35, No. 1, pp. 143–152, 2004.

    Article  Google Scholar 

  32. Morrow, W., Qi, H., Kim, I., Mazumder, J., and Skerlos, S., “Environmental Aspects of Laser-Based and Conventional Tool and Die Manufacturing,” Journal of Cleaner Production, Vol. 15, No. 10, pp. 932–943, 2007.

    Article  Google Scholar 

  33. Heigel, J., Gouge, M., Michaleris, P., and Palmer, T., “Selection of Powder or Wire Feedstock Material for the Laser Cladding of Inconel® 625,” Journal of Materials Processing Technology, Vol. 231, pp. 357–365, 2016.

    Article  Google Scholar 

  34. Ahn, D.-G., “Direct Metal Additive Manufacturing Processes and their Sustainable Applications for Green Technology: A Review,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 4, pp. 381–395, 2016.

    Article  Google Scholar 

  35. PG Photonics, “Fiber Laser Energy Savings Calculator,” https://doi.org/japanese.ipgphotonics.com/energy_calculator.htm (Accessed 1 AUG 2018)

  36. Jackson, M. A., Van Asten, A., Morrow, J. D., Min, S., and Pfefferkorn, F. E., “A Comparison of Energy Consumption in Wire-Based and Powder-Based Additive-Subtractive Manufacturing,” Procedia Manufacturing, Vol. 5, pp. 989–1005, 2016.

    Article  Google Scholar 

  37. Hendrickson, C. T., Horvath, A., Joshi, S., Klausner, M., Lave, L. B., et al., “Comparing Two Life Cycle Assessment Approaches: A Process Model vs Economic Input-Output-Based Assessment,” Proc. of IEEE International Symposium on Electronics and the Environment, pp. 176–181, 1997.

    Google Scholar 

  38. Herrmann, I. T. and Moltesen, A., “Does it Matter which Life Cycle Assessment (LCA) Tool you Choose?-A Comparative Assessment of Simapro and GaBi,” Journal of Cleaner Production, Vol. 86, pp. 163–169, 2015.

    Article  Google Scholar 

  39. Taylor, J., “Introduction to Error Analysis, the Study of Uncertainties in Physical Measurements,” University Science Books, 2nd Ed., 1997.

    Google Scholar 

  40. Thinkstep, “GaBi Life Cycle Engineering Suite,” https://doi.org/www.gabisoftware.com/america/index/ (Accessed 9 AUG 2018)

  41. Manvatkar, V., Gokhale, A., Reddy, G., Savitha, U., and De, A., “Investigation on Laser Engineered Net Shaping of Multilayered Structures in H13 Tool Steel,” Journal of Laser Applications, Vol. 27, No. 3, Paper No. 032010, 2015.

    Article  Google Scholar 

  42. ASTM International, “Standard Test Methods for Tension Testing of Metallic Materials,” ASTM E8 / E8M, 2016.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI, 53706, USA

    Marcus A. Jackson, Arik Van Asten, Justin D. Morrow, Sangkee Min & Frank E. Pfefferkorn

Authors
  1. Marcus A. Jackson
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Arik Van Asten
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Justin D. Morrow
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sangkee Min
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Frank E. Pfefferkorn
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Frank E. Pfefferkorn.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jackson, M.A., Van Asten, A., Morrow, J.D. et al. Energy Consumption Model for Additive-Subtractive Manufacturing Processes with Case Study. Int. J. of Precis. Eng. and Manuf.-Green Tech. 5, 459–466 (2018). https://doi.org/10.1007/s40684-018-0049-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40684-018-0049-y

Keywords

Search

Navigation