Design and optimization of energy-efficient milling processes using a geometric physically-based process simulation

Wirtz, A.1, a; Biermann, D.1, b; Wiederkehr, P.2, c

Institute of Machining Technology, TU Dortmund University, Baroper Str. 303, D-44227 Dortmund, Germany
Chair 14 for Software Engineering – Virtual Machining, TU Dortmund University, Otto-Hahn-Straße 12, D-44227 Dortmund, Germany

a); b); c)


The increasing complexity of production processes, shortening product lifecycles and rising energy costs lead to an emerging need for an efficiency optimization approach including process simulations in factory adaption planning as well as in process planning. This paper presents a method for the design of milling processes by analyzing process times, energy consumption and process stability based on process simulations. By evaluating simplified virtually conducted processes, reasonable parameter value combinations can be selected efficiently and provide flexibility by generating multiple solutions. Using detailed process simulations and conducting iterative adjustments to ensure a sufficient workpiece quality, the selected parameter sets are transferred to actual NC processes.


Procedia CIRP, 88 (2020), pp. 270-275, doi: /10.1016/j.procir.2020.05.047