Research Article

Advances in Mechanical Engineering

2017, Vol. 9(9) 1–11
Ó The Author(s) 2017
Measuring and calculating the DOI: 10.1177/1687814017723293
journals.sagepub.com/home/ade
computer numerical control lathe’s
cutting power and total electric power
consumption based on servo
parameters

Zhao-hui Liu1,2, Wei-min Zhang1,3, Liang-bin Liu1,3 and Zhong-yue Xiao1,2

Abstract
Improving the energy efficiency of machine tools is the goal of sustainable development of the mechanical manufacturing
industry. The key is to measure or calculate energy efficiency conveniently and accurately. This article proposes a
method of calculating power by reading the computer numerical control system’s servo parameters from its current-
loop and speed-loop, establishing the relationships between cutting power, total power, and servo parameters, and using
these relationships for power prediction. Experiments were done on a computer numerical control lathe. The result
shows that this method has high precision, does not need additional sensors, and is independent of cutting process para-
meters, workpiece material, heat treatment state, and tools. This method may be used for developing a cutting power
management module integrated in the computer numerical control system with real-time monitoring power consump-
tion because the computer numerical control system can read servo parameters real time.

Keywords
Computer numerical control lathe, cutting, power consumption, servo parameters, measurement, calculation

Date received: 12 April 2016; accepted: 10 July 2017

Academic Editor: Ismet Baran

Introduction exists due to machine auxiliary operations, transmission

With the crisis of global climate warming and the increas-
ing of resource prices, the world community is facing the
dual challenges of resource depletion and environmental
pollution. Governments and industries are paying more
and more attention to issues of sustainable develop-
ment.1–4 The manufacturing industry is an important
wealth creator. However, it is a major natural resource
and energy consumer as well. Therefore, sustainable
manufacturing has become an international focus.4–6 The
energy efficiency problem of machine tools has become a
major focal point of both manufacturer and customer,
and also a hotspot of scientific researches.7,8
In metal removal machine tools, necessary energy is
used for material removal, but additional energy loss
parts friction, electrical components’ resistance, electro-
magnetic leakage, and so on.9–11 For computer numeri-
cal control (CNC) lathes, milling machines, machining
centers, and other machine tools, their spindles and
1
School of Mechanical and Energy Engineering, Tongji University,
Shanghai, China
2
School of Mechanical Engineering, Jinggangshan University, Ji’an, China
3
Advanced Manufacturing Technology Center (AMTC), Tongji University,
Shanghai, China
Corresponding author:
Zhao-hui Liu, School of Mechanical and Energy Engineering, Tongji
University, Shanghai 201804, China.
Email: jgsucad@126.com

Creative Commons CC-BY: This article is distributed under the terms of the Creative Commons Attribution 4.0 License
(http://www.creativecommons.org/licenses/by/4.0/) which permits any use, reproduction and distribution of the work without
further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
2 Advances in Mechanical Engineering
feed-axes (servo) motion are usually driven by motors,
and some of auxiliary operations are driven by the com-
pressed air generated by an electric air compressor.
However, usually the energy required for compressed
air is a small part of the total electrical energy consump-
tion12,13 Therefore, in this article, energy required to
generate compressed air is not considered.
The total energy consumption of machine tool can
be easily measured by a power meter, which meets the
accuracy requirements for cutting parameters optimiza-
tion.14–16 But, for machine tool improvement research,
W Li et al.15 and A Zein16 propose that energy break-
down analysis should be done to measure the energy
consumption for each component. It is necessary to
monitor the energy consumption of machine compo-
nents, especially the material removal power (cutting
power) to properly perform machine tool energy effi-
ciency research.17,18 In current machine tool’s energy
consumption research, the input and output power of
electrical components can be measured or calculated by
the acquired signals with current, voltage, or power
sensors, which can be integrated in CNC system.15,16
However, the measurement and calculation of cutting
power is relatively complicated.
In current research, there are four typical methods
for cutting power measurement and calculation,
namely, (1) calculation by the classic theoretical cutting
force formula and motor speed, (2) calculation by an
improved formula through material removal rate
(MRR) and specific energy consumption (SEC), (3) cal-
culation by measuring cutting force and motor speed,
and (4) calculation by measuring electrical input power
and transmission mechanism efficiency.
In method (1), the cutting power can be calculated
by multiplying cutting force and cutting speed. Several
texts, including the studies of Rao19 and Shaw,20 pro-
vide a cutting force formula, which involves with the
cutting process parameters (cut-depth, cutting speed,
and feed rate), tool angle, workpiece material, and its
heat treatment. B Wang et al.21 propose energy optimi-
zation using cutting parameters and tool angle. If the
process involves variable cutting speed, the speed should
also be calculated or measured. This method has a rela-
tive large error and cannot perform energy monitoring
online real time. In method (2), the cutting power can
be calculated by multiplying SEC and MRR. A Zein16
and Yoon et al.22 research shows that the material SEC-
MRR curve varies with different machine tools. To
obtain this curve for a material in a certain machine
tool, experiments must be done to reduce errors. Due to
the different MRR-SEC curves of different machine
tools, this method is not suitable for real-time cutting
power monitoring unless the curve is obtained.
In method (3), the cutting power can be calculated
by multiplying cutting force and cutting speed. The key
is acquiring torque or force from a dynamometer23 or
strain gauge.20 Similar to method (1), cutting speed
acquisition method must also be considered. Because
the strain gauge has a short lifetime and complicated
wiring, and the dynamometer is expensive, this method
is not suitable for integration in the CNC machine tool
system. In method (4), the cutting power can be calcu-
lated by multiplying electrical input power and trans-
mission mechanism efficiency. S Hu et al.24 and F Liu
et al.25 proposed calculating or acquiring input power
using current, voltage, or power sensors and also pro-
posed calculating the transmission efficiency by analyz-
ing the mechanism transmission chain. From these, the
cutting power can be calculated. Principles of alternat-
ing current (AC) and direct current (DC) motors and
the structure of transmission mechanism must be taken
into account. The error is closely related to the compu-
tational model. This is also not the most suitable
method for integration in the CNC system.
It is noteworthy that Kim GD and Chu CN,26 X Li
et al.,27 and S Aggarwal et al.28 proposed indirect cutting
force measurement by monitoring motor current. This
method has good accuracy and can also be used for indi-
rect energy measurement. With the development of tech-
nology for digital servo controllers, intelligent components
integrated with internal and external sensors are widely
adopted in CNC machine tools.28,29 The motor current
signal and speed controlled by the digital servo can be
read out and written by the CNC and PC real time. This
is a novel indirect method to measuring and calculating
information such as cutting power and input power.
The purpose of this article is to propose an indirect
method of calculation cutting power and total power
using servo parameters related with the motor current
and motor rotation speed. This method is independent
of external sensors, cut-depth, cutting speed and feed
rate, tool, workpiece material, heat treatment state, and
it can be easily integrated in the CNC system.
Energy flow of the CNC machine tool and
servo control parameters
Energy flow of the CNC machine tool
The modern CNC machine tool commonly consists of
CNC system, servo control system, feedback equip-
ment, machine bed, lubricant, cooling system, and so
on. Most machine tools are driven by electrical energy,
where a part of the electrical energy is used to drive
servo systems, and the remaining power is used drive
lubricant, cool, display information, and other auxili-
ary functions. For most servo systems, the AC is first
converted to DC through a power supply module
(PSM), then PSM supplies energy to spindle amplifier
module (SPM) or the feed-axis (servo) amplifier mod-
ule (SVM), respectively, driving the spindle motor rota-
tion and feed-axis motor rotation or stalling. Taking
Liu et al. 3

Table 1. Definition of energy consumption components’ power.

Name Definition Name Definition

Pi Machine tool input power PCOOL Power of cooling system

PSYS CNC system, lubrication running power PiPSM PSM input power
PPSML PSM loss power PoSPM PSM output power
PiSPM SPM input power PiSVM SVM input power
PSPML SPM loss power PSVML SVM loss power
PoSPM SPM output power PoSVM SVM output power
PMoSPL Spindle motor loss power PMoSVL Feed-axis motor loss power
PoSP Spindle motor output power PoSV Feed-axis motor output power
PMeSPL Spindle output mechanical loss power PMeSVL Feed-axis output mechanical loss power
PSP Spindle output power PSV Feed-axis output power

CNC: computer numerical control; PSM: power supply module; SPM: spindle amplifier module; SVM: feed-axis (servo) amplifier module.

Figure 1. Energy/power flow of CNC machine tool.

the CINCINNATI HTC-200M lathe center equipped this article considers only the energy consumed by spin-
with FANUC 16i as an example, its energy (power) dle PSP as the effective cutting power
flow is as shown in Figure 1, and the definition of each
energy consumption components’ power is shown in Pi = PCOOL + PSYS + PiPSM
Table 1. = PCOOL + PSYS + PiPSML + PoPSM ð1Þ
The relationship of each component power in = PCOOL + PSYS + PiPSML + PiSPM + PiSVM
Figure 1 is shown as equations (1)–(3). A Zein16 and R
Sudarsan et al.17 and the experimental results in this PiSPM = PSPML + PoSPM = PSPML + PMoSPL + PoSP
ð2Þ
article show that PCOOL, PSYS can be considered as = PSPML + PMoSPL + PMeSPL + PSP
constant values, and there is a strong correlation
between PSM input power PiSPM and cutting power PiSVM = PSVML + PoSVM = PSVML + PMoSVL + PoSV
ð3Þ
PSP. In CNC lathe, the main function of the servo axis = PSVML + PMoSVL + PMeSVL + PSV
is to drive the servo axis’ motion or stalling. There is
relatively little power used when the servo axis is stal-
ling or moving at a low feed rate. The experimental Numerical servo system parameters
results in this article also prove that the servo axis For the closed-loop or semi closed-loop control CNC
energy power PSV is far less than the spindle power PSP system, the ‘‘three-loop’’ control method (the current-
in low feed rate cutting, when PiSVM \\ PiSPM; so, loop, speed-loop, and position-loop) is mostly adopted.
4 Advances in Mechanical Engineering
Figure 2. The three-loop control method of FANUC CNC system.
Figure 3. Relationship between output power, torque, and rotation speed of FANUC aiI22/7000HV motor.30
A typical FANUC system ‘‘three-loop’’ is shown in
Figure 2.29 Current, speed, and other signals of servo
motor are monitored by internal and external sensors
as parameters stored in servo controller; by altering
related parameters, the controller can also adjust to
keep the motor’s speed and input current consistent
with the set value. In a full digital servo system, the
CNC system can bidirectionally communicate with
the servo controller to read or write parameters to
set value, and it can also communicate with a PC.
Taking the FANUC 16i system as an example, the
CNC system monitors the motor current and speed in
real time through a servo controller, internal, and
external sensors and generates the command torque
(TCMD) according to those data. The servo controller
adjusts its output current based on the TCMD to main-
tain current-loop control. In a modern CNC system, a
permanent magnet synchronous motor (PMSM) is gen-
erally used for the feed-axis motor and asynchronous
induction for the spindle motor. The spindle motors
adopt a constant torque and constant power control
method. The feed-axis motors adopt a constant torque
control method. Figure 3 shows the relationship
between output power, torque, and rotation speed of
FANUC aiI22/7000HV spindle motor.30
Due to the electrical impedance, electromagnetic
saturation, and other factors, the relationship between
output torque and motor input current appears non-
linear when the current is close to the maximum or 0
values, while it appears linear when in the other
ranges. In a FANUC system, the servo parameter
SPEED is for the speed value of motor detected
through the internal sensor, which is of high accuracy.
The unit of SPEED is revolutions per minute (r/min).
The servo parameter TCMD is the current regulation
command for servo motor, which has an approxi-
mately linear relationship with the motor output tor-
que Me. The value of TCMD can be the current value
Liu et al. 5

Figure 4. Schematic diagram of the measurement system.

Table 2. HTC-200M CNC lathe servo controllers and servo motors.

Servo controller Servo motor

Model Model Type Rated power (kW) Maximum torque (N m)

Spindle aiSP30HV aiI22/7000HV A06B-1511-B153 22 162

Z-axis aiSV20/40HV aiF12/3000HV A06B-0245-B101 3 35
X-axis aiF8/3000HV A06B-0229-B401 1.6 29

CNC: computer numerical control.

or the ratio of the current to the maximum current. In
this article, the TCMD value is the ratio of the current
to the maximum current; its unit is %.
Based on this, the nominal power of the motor PST is
defined in this article, which is calculated by TCMD and
SPEED. The spindle motor adopts constant torque and
constant power control method as shown in Figure 3; when
the motor speed SPEED  1500, PST is calculated with
equation (4) and when SPEED . 1500, with equation (5)
2p  Tmax
PST = Me  v = TCMD  SPEED
60
PST = Pmax  TCMD
where Tmax is spindle motor maximum torque and Pmax
is spindle motor maximum power.
Experimental research
Experimental equipment
The HTC-200M CINCINNATI CNC lathe with a
FANUC 16i system with servo controllers is used in
this experiment. The servo motors are shown in Table
2. This lathe’s spindle motor is connected to spindle
through V-belt, and the transmission ratio (ratio of out-
put speed to input speed) is 0.9. The hollow cylindrical
workpiece material is ASTM 1045 (Hardness HBS:
205), with an outer diameter of 140 mm, an inner dia-
meter of 90 mm, a length of 180 mm. The experimental
scheme is shown in Figure 4, and the field wiring is
shown in Figure 5.
The TCMD and SPEED value of spindle servo con-
troller are read through FANUC SERVO GUIDE soft-
ware with a dedicated Personal Computer Memory Card
International Association (PCMCIA) card; then, the nom-
inal power PST is calculated according to equation (4) or
(5). A Hioki 3390-10 power analyzer is used to measure
the input power PiSPM and output power PoSPM of the
ð4Þ
SPM module and the input power PiSVM of SVM module.
ð5Þ The CNC lathe input power Pi and PSM module input
power PiPSM are measured using a power transmission
sensor (model: CE-P31-84DS5-0.5; Shenzhen SSET Co.,
Ltd, Shenzhen, China) and acquired using data acquisition
cards (model: USB2850; Beijing ART Technology
Development Co., Ltd, Beijing, China). The cutting forces
are measured using Kistler 9129A dynamometer, and the
cutting power PSP is calculated with equation (6).
MATLAB software is used to sample and analyze the
experiment data
FY  VC
PSP = ð6Þ
60
where FY (unit: N) is for the main cutting force and VC
is the cutting speed (unit: m/min).
6 Advances in Mechanical Engineering

Figure 5. Measurement field: (a) Machine tool & instruments, (b) Part support, (c) Power measurement wiring, and (d) Power
analyzer.

Table 3. Cylindrical longitudinal turning test process parameters.

No. ap (mm) f (mm/r) VC (m/min) No. ap (mm) f (mm/r) VC (m/min) No. ap (mm) f (mm/r) VC (m/min)

1 0.2 0.1 370 11 0.8 0.3 193 21 1.6 0.5 170

2 0.2 0.2 475 12 0.8 0.4 217 22 2 0.2 193
3 0.2 0.3 550 13 0.8 0.5 240 23 2 0.3 170
4 0.4 0.1 475 14 1.2 0.2 217 24 2 0.4 240
5 0.4 0.2 550 15 1.2 0.3 240 25 2.25 0.225 170
6 0.4 0.3 370 16 1.2 0.4 170 26 2.25 0.3 205
7 0.6 0.1 550 17 1.2 0.5 193 27 2.25 0.375 240
8 0.6 0.2 370 18 1.6 0.2 240 28 2.5 0.225 205
9 0.6 0.3 475 19 1.6 0.3 217 29 2.5 0.3 240
10 0.8 0.2 170 20 1.6 0.4 193 30 2.5 0.375 170

Experiment scheme
Cylindrical longitudinal turning experiment. The hollow
cylindrical workpiece is clamped with chuck and sup-
ported with a center as shown in Figure 5(b). Two kinds
of tool inserts are used for the longitudinal turning
experiment, where the SECO SMG4Ver1 insert is used
for finish turning, and the SANDVIK CoroKey 4235
insert is used for semi-finish and rough cutting. These
inserts are installed in the SANDVIK DCLNL2525M
shank. In total, 30 sets of parameters are selected for
this experiment, as shown in Table 3. No. 1–9 are finish
turning parameters for a Taguchi L9 orthogonal table;
No. 10–25 are semi-finish turning parameters for a
Taguchi L16 orthogonal table; No. 26–30 are part of
rough parameters as a Taguchi L9 orthogonal table.
Those parameters with cut-depth ap: 0.2;2.5 mm, feed
rate f: 0.1–0.5 mm/r, and cut speed VC: 170–550 m/min
Liu et al. 7

Table 4. Variable cut-depth turning test process parameters.

No. ap (mm) f (mm/r) VC (m/min) No. ap (mm) f (mm/r) VC (m/min)

31 2.2–0.2 0.1 370 35 2.2–0.2 0.2 475

32 0.2–2.2 0.1 475 36 0.2–2.2 0.2 550
33 2.2–0.2 0.1 550 37 2.2–0.2 0.3 370
34 0.2–2.2 0.2 370 38 0.2–2.2 0.3 475

Figure 6. Variable cut-depth cutting scheme: (a) taper turning and (b) variable cut-depth turning.

record the values of Pi, PiPSM, PiSPM, PoSPM and calcu-
late PST, PSP according to equations (4)–(6).
Variable cut-depth cutting experiment. On the same lathe,
using the SECO SMG4Ver1 insert and the hollow cylin-
der workpiece, the taper and variable cut-depth turning
are done, respectively, as shown in Figure 6. The cut-
depth varies from 0.2 to 2.2 mm, and the other process
parameters are show in Table 4.
Results and analysis
Correlation analysis of powers
According to the cylindrical longitudinal turning
experiment scheme, each power under the cutting and
unloaded states was recorded, as shown in Table 5.
According to the data in Table 5, the relevance can be
calculated as shown in Table 6, which shows a good
correlation between these power values. Linear regres-
sion analysis with PST as the independent variable, and
Pi, PiPSM, PiSPM, PoSPM, PSP as the dependent vari-
ables, the relational model is built in the form of
f(PST) = p1 * PST + p2. The linear equation coeffi-
cients p1 and p2, fitting coefficient R2, fit correlation
coefficient AdjR2, total deviation SSE and mean square
deviation RMSE, which are calculated out through the
regression, are shown in Table 7, and the fitting curves
are shown in Figure 7. These results indicate that the
fitting results have a good fitting degree.
Prediction of cutting power and machine tool power
The regression equations with coefficients calculated in
section ‘‘Correlation analysis of powers’’ are verified by
applying the cutting parameters in section ‘‘Variable
cut-depth cutting experiment.’’ Because of the continu-
ous variation of cut-depth, the main cutting force and
cutting power are continuously changing. The nominal
power PST value is calculated using the SPEED and
TCMD values monitored by the SERVO GUIDE soft-
ware and used to predict the value of other power. Note
these predicted values, respectively, Pi(P), PiPSM(P),
PiSPM(P), PoSPM(P), PSP(P). The powers measured by
monitoring instruments are, respectively, Pi(R),
PiPSM(R), PiSPM(R), PoSPM(R), PSP(R). Figure 8(a)
and (b), respectively, shows the comparison of pre-
dicted values and the actual measured values with the
No. 31 and 38 set of parameters. According to the com-
parative analysis of the predicted values and the actual
measured values, the relative errors of the predicted val-
ues calculated with equation (7) are shown in Table 8.
The results show that with the increase in cutting
power, the relative error between the predicted value
and the actual value will increase
P(P)  P(R)
err = 3 100% ð7Þ
P(R)
where err is the relative error, P(P) is the
power predicted value and P(R) is the measured power
value.
 8
Table 5. Cylindrical longitudinal turning test data.

No. St. Pi (W) PiPSM (W) PiSPM (W) PoSPM (W) PSP (W) PST (W) No. St. Pi (W) PiPSM (W) PiSPM (W) PoSPM (W) PSP (W) PST (W)

1 A 1488 572 480 447 0 161 16 A 1287 374 290 243 0 54

B 2066 1122 1025 907 297 619 B 5737 4682 4588 4248 3171 2804
2 A 1652 734 681 636 0 227 17 A 1367 451 346 313 0 57
B 2875 1904 1814 1676 517 1214 B 7039 5943 5853 5483 4195 3731
3 A 1949 1027 744 643 0 250 18 A 1334 420 345 293 0 81
B 3652 2656 2557 2402 1024 1791 B 5904 4839 4752 4426 3402 2984
4 A 1642 723 637 595 0 247 19 A 1327 412 314 271 0 65
B 3148 2170 2068 1919 907 1391 B 6938 5836 5739 5370 4047 3643
5 A 1793 874 882 811 0 264 20 A 1292 378 297 253 0 57
B 4253 3241 3130 2957 1736 2242 B 7721 6595 6496 6081 4587 4195
6 A 1565 648 560 529 0 132 21 A 1274 360 284 236 0 52
B 3974 2970 2872 2673 1667 1885 B 8261 7116 7009 6553 4953 4713
7 A 1764 843 745 672 0 339 22 A 1305 391 304 260 0 67
B 4105 3096 2991 2823 1851 2181 B 5650 4596 4486 4164 3175 2766
8 A 1512 595 502 476 0 149 23 A 1285 372 285 237 0 56
B 4143 3135 3037 2834 1811 2002 B 6762 5669 5564 5183 4004 3504
9 A 1706 787 973 912 0 162 24 A 1363 448 386 319 0 86
B 6063 5002 4896 4658 3332 3425 B 11,606 10,372 10,272 9743 7608 7043
10 A 1266 352 279 214 0 51 25 A 1261 347 282 213 0 51
B 3107 2128 2051 1815 1334 1159 B 6330 5258 5129 4738 3771 3126
11 A 1292 378 292 249 0 59 26 A 1264 351 278 210 0 52
B 3873 2873 2788 2536 1805 1654 B 6308 5226 5163 4773 3774 3160
12 A 1329 414 338 301 0 63 27 A 1311 396 314 264 0 65
B 4959 3929 3838 3554 2497 2374 B 8366 7225 7121 6687 5439 4675
13 A 1387 472 413 391 0 77 28 A 1421 505 388 346 0 80
B 6081 5010 4914 4601 3345 3095 B 11,218 9981 9862 9368 7760 6826
14 A 1329 415 327 287 0 78 29 A 1326 411 323 277 0 76
B 4380 3366 3271 3013 2138 2014 B 7428 6327 6221 5840 4736 3999
15 A 1369 454 367 336 0 84 30 A 1391 476 407 370 0 72
B 6028 4960 4870 4559 3394 3121 B 10,107 8920 8799 8360 6912 6064

St. is the working status; St. A is under unloaded operation, the cutting force FY value measured by Kistler is 0, so the calculated cutting power PSP is 0 according to the formula (6); St. B is under loaded
operation.
Advances in Mechanical Engineering
Liu et al. 9

controller parameters has a good correlation with the

Table 6. Power correlation analysis. cutting power PSP and the powers Pi, PiPSM, PiSPM
measured in other locations. In the variable cut-depth
Pi PiPSM PiSPM PoSPM PSP PST
cutting experiment, the equations are used for powers
Pi 1.000 1.000 1.000 1.000 0.996 0.998 prediction, which shows the result has good accuracy
PiPSM 1.000 1.000 1.000 1.000 0.996 0.998 with relative error within 8%.
PiSPM 1.000 1.000 1.000 1.000 0.996 0.998 The reason is that the spindle motor is a digitally
PoSPM 1.000 1.000 1.000 1.000 0.996 0.998
controlled AC motor, so the value of TCMD parameter
PSP 0.996 0.996 0.996 0.996 1.000 0.993
PST 0.998 0.998 0.998 0.998 0.993 1.000 has an approximately proportional relationship to the
motor output torque. The cutting force is relatively
small, where there is no V-belt slipping phenomenon;
so, the real speed of motor can be calculated accurately
Table 7. Linear regression results.
using SPEED parameter and mechanism transmission
p1 p2 R2 AdjR2 SSE RMSE ratio. The nominal power PST is calculated through
TCMD and SPEED, which leads to PST which has a
Pi 1.499 1266 0.9963 0.9962 1.76e + 06 115.9 good linear relationship with cutting power PSP. When
PiPSM 1.451 353.4 0.9962 0.9962 1.664e + 06 169.4 the servo axis is working at low speed, the cutting force
PiSPM 1.455 274.8 0.9958 0.9957 1.842e + 06 178.2
PoSPM 1.366 223.5 0.9966 0.9965 1.328e + 06 151.3 has little effect on the servo power. Therefore, PiSVM is
PSP 1.14 2184.4 0.9869 0.9865 3.6e + 06 249.1 much smaller than PiPSM and can be neglected. In sum-
mary, Pi, PiPSM, PiSPM have a good linear relationship
SSE: sum of squares due to error; RMSE: root mean squared error. with cutting power PSP.
The method to predict cutting power and machine
Conclusion and discussion tool power through servo parameters is independent of
the workpiece, tool, and cutting process parameters.
The longitudinal turning experimental results show that The CNC system can read the servo parameters in real
the nominal power PST calculated through servo time, which enables the integration of the energy

Table 8. Prediction error analysis.

No. Pi (%) PiPSM (%) PiSPM (%) PoSPM (%) PSP (%) No. Pi (%) PiPSM (%) PiSPM (%) PoSPM (%) PSP (%)

31 2.04 0.75 2.61 2.89 25.45 35 4.49 3.63 5.38 4.79 1.54
32 2.44 0.85 2.81 2.90 24.65 36 4.42 4.52 5.15 4.71 1.51
33 2.87 1.31 3.07 3.28 22.84 37 5.76 5.25 6.36 5.84 3.05
34 2.92 2.19 3.58 3.80 20.20 38 6.81 6.78 7.72 6.81 3.88

Figure 7. Relationship between PST and other power.

10
Figure 8. Comparative analysis of predicted and actual values: (a) No.31: ap = 2.2–0.2, VC = 370 m/min, f = 0.1 mm/r and (b) No.38:
ap = 2.2~0.2, VC = 475 m/min, f = 0.3 mm/r.
consumption monitoring module in the CNC system,
and this method will provide a reference for the
machine tool or CNC system manufacturers to develop
the energy consumption monitoring module.
The drawbacks of this method are as follows: (1) the
relationship between TCMD and actual torque is
obtained by the regression of experimental data,
resulting in a relatively large error; (2) when the motor
rotation speed is near the high-limit or low-limit
speed, the relationship between TCMD and actual
torque may be more complicated, where more detailed
information is needed from CNC system, servo, and
motor manufacturer; (3) for high-speed machining,
the feed-axis power is relatively large and cannot be
neglected.
Follow-up studies will focus on the relationship
between the feed-axis motor power and servo
Advances in Mechanical Engineering
parameters, especially under conventional cutting and
high-speed cutting, and the establishment of a calcula-
tion algorithm for power, energy, and efficiency of con-
ventional cutting and high-speed cutting. Further
research on improving the algorithm will improve
machining energy consumption prediction and energy
efficiency–based machining process parameters optimi-
zation. Eventually, the algorithm will be integrated into
the CNC system, and energy consumption on-machine
monitoring and manufacturing system energy con-
sumption management based on INTERNET plat-
forms will be realized.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Liu et al.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
article: The project was supported by the National Science
and Technology Major Project of the Ministry of Science and
Technology of China (grant no. 2012ZX04005031).
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