A Dynamic Simulation Model for Understanding Sustainability of Machining Operation

The environmental impact of machining operations such as milling, drilling, and turning, is often treated as a conflicting interest when compared to other machining factors such as cost, quality, time, and process settings. It is more beneficial in the long-term for the manufacturer to adjust their practices to be more environmentally conscious. Currently, there are limited existing research showing the linkages between environmental impact of machining and other machining factors. The objective of this study is to create a systems model to examine the linkages of environmental impact with cutting conditions, cost, quality, and efficiency. The model aims to replicate the machining behaviors at the unit process level and generate the long-term implications of their techniques and impacts for engineering decision making. A case study was conducted on a CNC machining operation to create injection molds for climbing holds. The model simulates tool wear and replacement, cutting, energy, cost, and surface quality. The result of this study contributes to the manufacturing knowledge by creating a systems model to quantify and better understand the linkages and trade-offs between environmental impact and decisions surrounding machining operation parameters and technologies. The self-governing behavior of the dynamic model can also be used as a decision-making tool for smart machining control.