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Evaluation of energy consumption and carbon emission in EDM

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Abstract

Green manufacturing is one of the most important development directions in mechanical processing field. Electrical discharge machining (EDM), one of the non-traditional machining, is increasingly used. However, there were hardly any studies on the evaluation of energy consumption and carbon emissions in EDM. In this study, a quantitative assessment model of carbon emission in EDM was built based on the emission factor method. The tool electrode wear, harmless treatment of residual tool electrodes and working fluid, and electrical energy consumed by the equipment were considered in this assessment model. EDM drilling experiments were conducted to verify the effectiveness of the proposed model. The effects of pulse width, pulse interval, and peak current on machining time, surface roughness, energy consumption, and carbon emissions were analyzed. The CNC system, cooling system, and power supply consumed about 95% of the total energy. In small hole EDM drilling, the total carbon emissions from the preparation and waste residue treatment of workpiece and tool electrode were almost negligible due to the small material removal volume. The carbon emissions generated by electrical energy consumption account for about 50% of the total carbon emissions. Carbon emissions can be minimized to 72 g and energy consumption can be reduced to a minimum of 37.48 Wh when processing a small hole with the diameter of 1 mm and the depth of 6 mm by EDM drilling.

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Funding

The authors appreciate the support from the National Natural Science Foundation of China (No.52005298), Young Scholars Program of Shandong University, Weihai, (No.202209), the Natural Science Foundation of Shandong Province (No. ZR2021ME048), and Innovation Ability Enhancement Project of Small and Medium-sized Enterprises of Shandong Province (No.2023TSGC0305). This work was also supported by the Physical–Chemical Materials Analytical & Testing Center of Shandong University at Weihai.

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Authors and Affiliations

  1. School of Mechanical, Electrical & Information Engineering, Shandong University, Weihai City, 264209, People’s Republic of China

    Jiuyong Xu, Kan Wang & Yong Liu

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture (Ministry of Education), School of Mechanical Engineering, Shandong University, **an, 250061, People’s Republic of China

    Qinhe Zhang

  3. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, **an, People’s Republic of China

    Qinhe Zhang

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  1. Jiuyong Xu
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Contributions

Jiuyong Xu performed the experiment, the data analyses, and wrote the manuscript; Kan Wang contributed to the conception of the study and edited the manuscript; others helped perform the analysis with constructive discussions.

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Correspondence to Kan Wang.

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Xu, J., Wang, K., Liu, Y. et al. Evaluation of energy consumption and carbon emission in EDM. Int J Adv Manuf Technol 132, 1511–1524 (2024). https://doi.org/10.1007/s00170-024-13469-z

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