Energy consumption assessment and economic analysis of a novel sustainable electro-machining auxiliary system

In contrast to traditional machining methods, electro-machining presents a new opportunity for treating materials that are problematic for conventional approaches. While gaining increasing prominence in the manufacturing industry, electro-machining is marked by heightened energy consumption and reduced operational efficiency. A comprehensive survey of electro-machining manufacturing facilities has identified two pivotal factors influencing energy consumption and efficiency enhancements: 1) determining optimal electrical parameters for electro-machining during the production planning stage, and 2) timely adjustment of electro-machining parameters throughout the production stage. To address these two challenges, an innovative model-based electro-machining auxiliary system has been introduced for the surveillance and optimization of the machining process. The system aims to curtail energy consumption, enhance machining efficiency, and fortify economic viability, all while maintaining machining quality. Notably, the system demonstrates adaptability in deriving optimized electrical parameters tailored to diverse processing conditions. Energy consumption evaluation and techno-economic analysis, employing primary industry data, were conducted to compare the energy efficiency and economic performance of the machining process with the new auxiliary system against the conventional approach. The foremost outcome of adopting the new auxiliary system is a substantial reduction in energy usage; from an economic standpoint, the analysis shows that the cost of machining a single workpiece is reduced by 27.75%; the energy efficiency analysis reveals a 27.75% decrease in energy consumption per unit area, accompanied by an approximately 30% increase in machining efficiency. The proposed approach has demonstrated significant practical value for the sustainable development of the electro-machining process.