1. Modeling the Power Consumption of a Fadal VMC20 Milling Machine Mark Hansen, EE Student Department of Industrial and Manufacturing Engineering Green Manufacturing Faculty Advisors: Dr. Janet Twomey, Dr. Bayram Yildirim, Dr. Lawrence Whitman, Dr. Jamal Sheikh-Ahmad Green Manufacturing Team Members: Rebekah Drake, Prashant Lodhia Supported by NSF CAREER: DMI-973347

2. Energy and Manufacturing Overall Research Objective –To identify the environmental impacts of the manufacturing system so that we can mitigate their adverse impacts –My responsibilities as the E E on the team A Problem in Manufacturing –Energy consumption impacts the environment. –By describing and predicting energy consumption, we can find ways to mitigate those impacts. A Starting Point –Modeling the energy consumption of a single milling machine.

3. Experimental Setup

4. Machine: Fadal VMC20 Vertical Milling machine Procedure: Manufacture a simple aluminum part Data Collection: Sampling total instantaneous power consumption of the machine Experimental Setup

5. The Machine Spindle Coolant Pump Lights and Controls Table

6. The Part 2 Holes 0.25’’ in Diameter 8mm Deep Y Cut 3’’ Long 0.04’’ Deep 8mm Aluminum X Cut 2.5’’ Long 0.04’’ Deep

7. The Data Collection Device Device Specs. –Portable device –Three-phase power measurement –Instantaneous measurement of both voltage and current –Maximum sampling rate of 250 samples per second

8. Data Analysis

9. Instantaneous Power Consumption

10. Machine Startup Lights & Controls

11. Instantaneous Power Consumption Coolant Pump Coolant Pump Startup

12. Coolant Pump Power-On Spike Spindle Startup Spindle Instantaneous Power Consumption

13. Rapid Axis Movement

14. Instantaneous Power Consumption Machining Startup TIP + Slow (Feed) Axis Movement

15. Percentage Energy Consumption Lights & Controls: 10,014 Joules Spindle: 9,647 Joules Tip + Axis Movement: 5,826 Joules Coolant Pump: 2,444 Joules Total Energy Consumed: 27,931 Joules (0.47 kWh)

16. Goals of Future Research Use this data to predict the energy consumption of a more complicated part, given the same machine and material, without repeating the data-collection and analysis. Simulate production runs of many parts over time.