Green CNC processing performance and optimization using I-optimal response surface design: an experimental study

Kiran Kumar M

doi:10.1080/10426914.2025.2559623

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Green CNC processing performance and optimization using I-optimal response surface design: an experimental study

2025-09-01

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Kiran Kumar M

Jagadish Jagadish *

Boby John

DOI：10.1080/10426914.2025.2559623

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Abstract

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This work aims to study the processing performance and optimize the CNC (Computer Numerical Control) turning process to reduce the environmental impact of CNC machining operations while maintaining efficiency and productivity. Experiments are conducted using an I-optimum design that takes into account four factors: spindle speed (x1), depth of cut (x2), feed rate (x3), and environment (x4) (wet and dry). The desirability function approach is used to evaluate the effects of these factors and optimize material removal rate (y1), surface roughness (y2), energy consumption (y3), and machining cost (y4). The optimal setting obtained is x1(250 rpm), x2 (1.5 mm), x3 (0.20 mm/min), and x4 (dry condition) and optimized responses are y1 (MRR) as 284.42 mm3/min, y2 (Ra) as 1.07 mu m, y3 (energy consumption) as 1769.44 kJ, and y4 (total machining cost) as Rs. 80.47, respectively. The findings of the study are validated through confirmatory trials. By implementing the results of the study, manufacturers can reduce the environmental footprint of machining operations and thus contribute to the overall goal of achieving a more sustainable manufacturing industry.

Keywords:

Green manufacturing

CNC machining

I-optimal design

RSM

ANOVA

desirability function

and optimization