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50% reduction in the energy consumption possible
10.03.2014

Increasing the efficiency of metal-cutting machining centres

Modern machine tools offer a diverse range of possibilities: they drill, mill, saw, turn and grind fully automatically. These production steps, which comprise the different metal-cutting processes, often only make up around 20% of the machine’s energy consumption. Most of the energy is consumed by peripheral systems such as the hydraulics, cooling and lubrication. The BINE-Projektinfo brochure “Making machine tools work more efficiently” (03/2014) presents a research project that analysed the energy consumption of the individual machine components and developed optimisation concepts. Energy savings of up to 50% are possible. In some cases the additional measures pay for themselves after just a few months.

The most energy intensive components in machine tools are the cooling lubricant systems, machine cooling and hydraulics. These formed the focus of the research work. For the investigations, a 4-axis machining centre was used similar to those deployed in the automotive industry, and which was re-equipped for research purposes. This has resulted in a diverse range of optimisation concepts for individual components. As part of the project, a software tool has also been developed that compares various configurations for machine tools and supplies analyses of the energy consumption and costs at an early stage.

The research project is being led by the Institute for Production Management, Technology and Machine Tools (PTW) at TU Darmstadt. Partner companies are also involved from the mechanical engineering, component manufacturing and automotive production fields.

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Downloadable pictures

Note: All downloadable pictures may only be used for coverage relating to this research project.

The BINE-Projektinfo "Making machine tools work more efficiently" (03/2014)

Minicover
(300 dpi, tiff, 1.2 MB)

4-axis machining centre MAG XS-211 (© TU Darmstadt).

Figure 1
4-axis machining centre MAG XS-211 (© TU Darmstadt).