Sustainable Operations and Computers 5 (2024) 73–87

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Sustainable Operations and Computers

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Sustainable CNC machining operations, a review

Mohsen Soori a,∗, Fooad Karimi Ghaleh Jough b, Roza Dastres c, Behrooz Arezoo d
a
Department of Aeronautical Engineering, University of Kyrenia, Kyrenia, North Cyprus, Via Mersin 10, Turkey
b
Department of Civil Engineering, Final International University, AS128, Kyrenia, North Cyprus, Via Mersin 10, Turkey
c
Department of Computer Engineering, Cyprus International University, North Cyprus, Via Mersin 10, Turkey
d
CAD/CAPP/CAM Research Center, Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), 424 Hafez Avenue, Tehran
15875-4413, Iran

a r t i c l e i n f o a b s t r a c t

Keywords: To minimize the quantities of carbon emissions produced by the production process, sustainable manufactur-
Sustainable CNC machining ing should be implemented. CNC machining operations can be made more sustainable by optimizing machining
Cutting tool paths optimization parameters to reduce material waste and energy consumption. In order to achieve sustainable CNC machining
Process planning of CNC machining
operations, cutting tool paths can be optimized. Investing in energy-efficient CNC machines can significantly re-
Energy efficiency of CNC machining
duce energy consumption to minimize the negative impact of CNC machining operations. Virtual simulation and
Virtual machining
analysis of CNC machining operations can be used to identify areas where sustainable practices can be imple-
mented in order to reduce waste and improve efficiency during machining operations. The study aims to provide
a comprehensive overview of the current state of sustainable CNC machining practices by summarizing the lat-
est research and developments in this field. It identifies the economic and environmental benefits of sustainable
CNC machining, such as reduced operational costs, improved resource utilization, and compliance with environ-
mental regulations. It offers insights into the latest advancements, practices, and future prospects, encouraging
manufacturers to embrace sustainable CNC machining as a pivotal step towards a greener and more efficient
manufacturing ecosystem. Thus, the efficiency and product safety of the process of producing parts with CNC
machine tools can be improved.

Introduction ing firms that are being pressured by customers and regulators to offer
environmentally friendly goods [5]. Moreover, safer production prac-
Several issues, including economic, social, environmental, and tech- tices improve worker, community, and product safety. Due to the fact
nical ones, are experienced in manufacturing environments. Natural re- that sustainability affects a wide range of industrial businesses, it has
source depletion and climate change are two examples of environmental become a very important study issue [6]. The use of sustainable manu-
issues. In manufacturing, it is another element that is required [1]. The facturing techniques and technology provides business with a practical
manufacturing sector, one of the major contributors to carbon emissions, means of enhancing social, environmental, and economic performance.
is currently under pressure from the economy and the environment, ” During a certain manufacturing activity, sustainable or green man-
with both calling for the implementation of low-carbon manufacturing ufacturing can be tackled in terms of reducing energy use, water use,
strategies by manufacturing companies [2]. Low carbon emissions, a re- emissions, the ideal supply pressure of cutting fluids, costs, safety, and
duction in the use of natural resources and energy sources, and other waste products [7]. Manufacturers should be able to compare and as-
environmental goals are all related [3]. To reduce pollution and the uti- sess current manufacturing technologies on the basis of sustainability in
lization of raw materials, increase energy efficiency, and recycle or reuse order to secure a sustainable and clean energy future. Sustainable manu-
trash are some of the environmental goals that have been introduced to facturing, often known as green manufacturing, aims to eliminate waste,
the industrial system. To advance toward sustainable production, these meet consumer demands for environmental performance, and lower en-
characteristics are combined [4]. ergy and material costs for greener goods [8]. Only through adopting
Sustainable manufacturing refers to the process of producing man- methods of process design, product design, and operational concepts
ufactured items in a way that minimizes their negative environmental that reduce energy and material consumption, the goals of green man-
consequences while saving energy and other resources. Sustainability ufacturing can be accomplished. Industries face rising global energy
evaluation is quickly becoming an indisputable concern for manufactur- and material costs together with rising expectations from consumers,

∗
Corresponding author.
E-mail address: [email protected] (M. Soori).

https://doi.org/10.1016/j.susoc.2024.01.001
Received 13 May 2023; Received in revised form 25 October 2023; Accepted 2 January 2024
Available online 26 January 2024
2666-4127/© 2024 The Authors. Published by Elsevier B.V. on behalf of KeAi Communications Co., Ltd. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
M. Soori, F.K. Ghaleh Jough, R. Dastres et al. Sustainable Operations and Computers 5 (2024) 73–87

investors, and communities. This demonstrates how SM is a must for energy. Cutting settings and tool route may both have a substantial im-
business [9]. pact on carbon emissions [16].
The machining procedure is an important manufacturing process Three key elements that have an influence on both ecological and
that is crucial for promoting sustainable production on the factory floor. financial restrictions may be used to gauge how sustainable a manufac-
One way to describe sustainable machining is as a machining process turing process is. These elements include the amount of energy needed
that can be maintained for a longer period of time while maintaining to execute a task, the materials used, and the amount of time needed
the same level of effectiveness. The social, economic, environmental, to complete the task [17]. To maximize process sustainability, a good
and technological aspects of the machining process are often preserved manufacturing system must be created, which requires the quantifica-
for a longer time frame to ensure sustainability [10]. By preserving en- tion and analysis of these parameters. In order to reduce energy usage,
ergy and natural resources, it decreases waste and its negative effects on cutting tools are used to remove material and to create features and sur-
the environment. As a "green manufacturing method," it is also known faces. Sustainability is based on non-polluting practices that conserve
by that name [11]. The sustainability impact of machining systems must natural resources, are economically viable, are safe for employees, and
thus be monitored, evaluated, and optimized using technologies, accord- take into account social, environmental, and economic issues [18]. One
ing to decision-makers. Modeling and simulation (M&S), which predicts of the main strategies for cutting back on resources and energy use is
the effects of installing a new facility or process without disrupting ac- to make processes and machinery more productive. The manufacturing
tual production, may be a successful instrument for the success of sus- methods have been meticulously designed to facilitate ongoing waste
tainable manufacturing [12]. The industrial sector, which has a signifi- elimination, reduction, or recycling. The objectives can be reached by
cant place in the machining industry, is crucial to the world economy. producing less waste, increasing recycling or reusing, using water prop-
Because of this, minimizing energy use in manufacturing processes that erly, wasting fewer resources and energy, avoiding metalworking fluids,
include machining has emerged as a key concern for environmentally and enhancing lubricating oil supervision, swarf management, and hy-
responsible manufacturing [13]. Studies and research are required on draulic oil management. Dry machining using coated cutting tools and
low-carbon manufacturing techniques with the goal of enhancing re- the use of cooling and lubrication fluids (CLFs) as alternatives can both
source use by lowering carbon density [14]. Machine tools are primar- contribute to sustainability [19]. Fig. 1 depicts the main factors to think
ily responsible for the energy consumption of industrial processes, thus about while machining sustainably [20].
realizing energy-efficient management of them is a useful strategy for Sustainability aspects of machining operations is presented in or-
energy conservation [15]. By analyzing the background runtime opera- der to achieve the sustainable manufacturing goals during part produc-
tions of machining (such as spindle, jog, coolant pump, computers, and tion process [21]. sustainability of machining processes is reviewed to
fans, etc.), it was possible to characterize the energy consumption of achieve a unified global index for sustainable machining design [22]. To
a mill, lathe, and injection molding machine. It was found that these increase productivity in machining processes, a study of sustainable ma-
background operations consume over 30 % of the energy input into the chining engineering with relation to the optimization procedure through
system during machining. Using control systems that lower energy us- triple bottom line is offered [23]. In comparison to CNC machining, lathe
age during a machine’s idle times is therefore one of the ways to save machining of stainless steel has shown to be more sustainable in terms

Fig. 1. The main factors to take into account while ma-

chining sustainably [20].

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Table 1
Recent achievements in sustainable CNC machining operations.

Topic of research work Papers Finding/ Discoveries

CNC machining parameters optimization [27] In order to decrease the environmental impact during machining operations of hard machining of AISI 304
stainless steel, grey fuzzy coupled Taguchi method is used.
[28] To provide the minimum quantity lubrication during milling operations of steel alloys, optimized machining
parameters are obtained.
[29] To provide sustainability in machining processes for Inconel 625, optimization process is implemented.
Cutting tool paths optimization [30] To minimize the operation time in turning of POM-C cylindrical stocks, optimized cutting tool paths are obtained.
[31] Cutting-Tool degradation in CNC machining operations is minimized using the optimized machining parameters.
[32] To optimize the cutting tool paths in orthogonal turning of AISI 310S, Genetic algorithm is used.
Process planning of CNC machining [33] Comprehensive digital evaluation of low-carbon machining process planning is presented using the fuzzy
statistical method.
[34] Multi-objective process planning is implemented to present sustainable CNC machining operations.
[35] Internet of thing application is used to obtain the smart system based on STEP-NC for machine vision.
Energy efficiency improvement of CNC machining [36] To provide sustainable CNC machining operations, optimization of resources is reviewed.
[37] Energy monitoring, evaluation, optimization and benchmarking during machining operations is reviewed to
provide sustainable manufacturing processes.
[38] Energy efficiency, carbon emissions and machining characteristics in machining operations are optimized to
provide sustainable machining operations.
Metal chips and swarf recycling in CNC machining [39] To decrease the environmental impacts of CNC machining, recycling of Ti6Al4V machining swarf is studied.
[40] Machining waste are converted into metal powder feedstock for additive manufacturing in order to decrease CNC
machining environmental pollutions.
[41] Metal powder from machining chips is produced in order to provide sustainable CNC machining operations.
Virtual simulation of CNC machining operations [42] To enhance sustainability in intelligent manufacturing, application of digital twin is studied.
[43] To enhance manufacturing sustainability in industry 4.0, application of virtual reality is studied.
[44] Digital twin-enabled machining process modeling is presented in order to improve the productivity as well as
sustainability in machining operations.

of reducing downtime in supply chains for replacement parts and com- curve for an SMRF structure using an adaptive neuro-fuzzy inference sys-
ponent inventories [24]. To achieve environmental goals throughout tem based on fuzzy C-means algorithm. Ghasemzadeh et al. [60] discuss
the component production process, the contribution of additive manu- identifying and contextualizing factors of infrastructure projects in or-
facturing applications to environmental sustainability is examined [25]. der to identify and demonstrate the current deficiency of using BIM for
To ensure industrial sustainability during the part production process, infrastructure projects. Treating Epistemic Uncertainty with a Group Ap-
an evaluation of the industrial sector’s mechanical manufacturing sys- proach to Data Handling Algorithm in Seismic Collapse Karimi Ghaleh
tems’ sustainability assessments is conducted [26]. Recent achievements Jough et al. [61] introduce fragility, which increases power and out-
in sustainable CNC machining operations is shown in the Table 1. put accuracy and precision while using the same amount of comput-
To evaluate and enhance CNC machining in virtual environments, ing time as the previously described approaches. Karimi Ghaleh Jough
Soori et al. proposed virtual machining approaches [45–48]. In order to and Ghasemzadeh [62] offer Uncertainty Interval Analysis of Steel Mo-
enhance the performances of CNC machining operations, machine learn- ment Frame by Development of 3D-Fragility Curves Towards Optimized
ing and artificial intelligence in CNC machining operations are reviewed Fuzzy Method in an effort to improve accuracy and shorten execution
by Soori et al. [49]. To analyze and increase the effects of coolant in time while driving the 3D-fragility curves. Karimi Ghaleh Jough [63]
turning operations, cutting temperature, tool wear and surface rough- examines the role of steel wallposts on the out-of-plane behavior of non-
ness are studied by Soori and Arezoo [50]. To examine and improve structural masonry walls in order to give reduced modification factors
efficiency in the process of component manufacture using welding pro- in masonry walls with wallposts.
cesses, Soori et al. [51] proposed an overview of recent advancements To enhance accuracy in 5-Axis milling operations of turbine blades,
in friction stir welding techniques. Soori and Asamel [52] investigated deformation error compensation is presented by Soori [64]. Surface
the utilization of virtual machining technologies to lessen residual stress roughness and residual stress in abrasive water jet cutting of titanium
and deflection error during turbine blade five-axis milling operations. In alloy Ti6Al4V is studied by Soori and Arezoo [65] in order to enhance
order to evaluate and lower the cutting temperature during milling oper- quality of produced parts using abrasive water jet cutting operations.
ations of difficult-to-cut components, Soori and Asmael [53] developed Drilling operations of titanium alloy Ti-6Al-4V is studied by Soori and
applications of virtualized machining systems. To improve surface qual- Arezoo [66] in order to minimize the Cutting tool wear during drilling
ity throughout turbine blade five-axis milling procedures, Soori et al. operations. In order to analyze and enhance the parameter optimiza-
[54] presented an enhanced virtual machining technique. In order to tion approach of machining operations, Soori and Asmael [67] offered
minimize deflection error during five-axis milling procedures of impeller a synopsis of current advances from published works. In order to in-
blades, Soori and Asmael [55] developed virtual milling procedures. crease energy usage effectiveness, data quality and availability through-
Karimi Ghaleh Jough and Şensoy [56] provide meta-heuristic meth- out the supply chain, and precision and reliability during the component
ods for evaluating the collapse risk of steel moment frame mid-rise struc- production process, Dastres et al. [68] conducted a research of RFID-
tures in an effort to improve risk management for steel moment frames. based wireless manufacturing systems. In order to increase efficiency
Karimi Ghaleh Jough and Şensoy [57] study Steel Moment-Resisting and added value in component production processes utilizing CNC ma-
Frame Dependability by Interval Analysis utilizing the FCM-PSO Method chining operations, Soori et al. [49] examined machine learning and ar-
to improve accuracy and reduce execution time in the estimation of tificial intelligence in CNC machine tools. To measure and reduce resid-
siesmic fragility curves. Karimi Ghaleh Jough and Golhashem [58] give ual stress during machining operations, Soori and Arezoo [69] provided
an assessment of the out-of-plane behavior of non-structural masonry a review in the subject. Soori and Arezoo [70] described optimal ma-
walls using FE simulations in an effort to lessen the self-weight axial chining settings utilizing the Taguchi optimization technique to reduce
compression of the walls made of contemporary lightweight masonry surface integrity and residual stress during grinding operations of In-
components. In order to incorporate epistemic uncertainty and increase conel 718. Soori and Arezoo [71] investigated several tool wear predic-
calculation accuracy, Karimi Ghaleh Jough and Beheshti Aval [59] im- tion techniques to lengthen cutting tool life during machining processes.
plemented uncertainty analysis through development of seismic fragility In order to increase efficiency in the component production process,

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Soori and Asmael [72] studied computer assisted process planning. In eration. Optimizing the cutting speed can significantly reduce energy
order to provide decision - making support systems for data warehouse consumption and material waste during machining operations. Also,
operations, Dastres and Soori [73] discussed Web-based decision sup- optimizing the feed rate can reduce the amount of material that is
port system improvements. In order to develop the implementation of removed, thereby minimizing waste. Reducing the depth of cut can
artificial neural networks in performance enhancement of engineering significantly reduce energy consumption and material waste [85].
products, Dastres and Soori [74] presented a review of recent research 3. Cutting tool selection: The choice of cutting tools, including their
and uses of artificial neural networks in a variety of disciplines, includ- material and geometry, can have a significant impact on the sus-
ing risk analysis systems, drone control, welding quality analysis, and tainability of the machining process. Durable and long-lasting tools
computer quality analysis. Dastres and Soori [75] discussed using infor- reduce waste and improve the overall efficiency of the process [86].
mation and communication technology in environmental conservation 4. Lubrication and cooling: The use of appropriate lubricants and
to lessen the impact of technological progress on natural disasters. Das- coolants can reduce tool wear and improve the surface finish while
tres and Soori [76] proposed the secure socket layer in order to improve also reducing energy consumption [87].
network and data online security. To identify and indicate the gaps be- 5. Waste management: The proper management of waste generated
tween the techniques that have been provided in order to create the during the machining process is crucial for sustainability. Recycling
methodology for decision support system, Dastres and Soori [77] ana- of chips and other waste materials can significantly reduce environ-
lyze the advancements in web-based decision support systems. Dastres mental impact [88].
and Soori [78] provided an assessment of current developments in net- 6. Machine maintenance: Regular maintenance of machines can im-
work threats in order to improve security measures in networks. Dastres prove their performance and reduce energy consumption, extending
and Soori [79] analyze image processing and analysis systems to expand their lifespan and reducing the need for replacement.
the possibilities of image processing systems in many applications.
The review paper is novel study in sustainable CNC machining oper- Optimizing these parameters can significantly improve the sustain-
ations by offering a fresh perspective on the integration of sustainabil- ability of CNC machining operations while also reducing costs and im-
ity principles into CNC machining processes. In this paper, a review of proving efficiency. optimization of turning process for the sustainable
sustainable CNC machining operations is presented in order to provide machining is presented in Fig. 2 [81].
the most recent developments from the published papers in the analysis In a decision-making approach for sustainable machining processes
and modification of advanced machining operations. The study intro- using data clustering and multi-objective optimization, the optimal cut-
duces innovative concepts and tools that can be applied by manufactur- ting parameters for various situations are selected, and the ability to
ers to achieve significant improvements in their operations in order to switch between clusters and/or scenarios with the least amount of ef-
decrease the environmental impacts of CNC machining operations. As a fort is also offered [89]. As a results, by implementing these strategies
result, sustainability as well as efficiency in process of part production and continuously monitoring and improving processes, CNC machining
using CNC machine tools can be enhanced. can become more sustainable, reducing its environmental impact while
Cutting tool paths as well as CNC machining parameters can be op- maintaining or improving productivity and profitability Fig. 3 [90].
timized in order to minimize the energy consumption during machining
operations. Metal chips and swarf during CNC machining operations can Cutting tool paths optimization
be recycled to decrease the environmental impact of metal cutting op-
erations. To enhance productivity during CNC machining operations, Sustainable CNC machining operations involve optimizing the cut-
virtual simulation and optimization can be implemented. ting tool paths in order to minimize waste, reduce energy consumption,
and extend the lifespan of the cutting tools [91]. Cutting tool path op-
CNC machining parameters optimization timization can reduce material waste, improve machining accuracy and
efficiency, and extend the life of cutting tools. Sustainable machining is
CNC machining parameters optimization is a crucial process in a holistic approach that involves not only optimizing cutting tool paths
manufacturing that aims to improve the efficiency, quality, and cost- but also considering material choices, machine efficiency, and waste re-
effectiveness of CNC machining operations. By optimizing machining duction [36,92]. Flowchart of tool-path optimization considering carbon
parameters, manufacturers can achieve better results, such as reducing emissions is shown in the Fig. 4.
cycle times, minimizing tool wear, and enhancing the surface finish of To minimize the energy usage during hole machining operations, an
machined parts [80]. Optimizing CNC machining parameters for sus- advanced optimization method of cutting tool path and cutting param-
tainability involves minimizing waste, energy consumption, and envi- eters is presented [94]. Flowchart of optimization of hole machining to
ronmental impact while maintaining or improving part quality [81,82]. minimize energy usage is shown in the Fig. 5 [94].
The process is essential for reducing energy consumption, material A manufacturing company’s efficiency can be raised by reducing pro-
waste, and environmental impact while maintaining or even improving cessing time in a production system [95]. The processing time and en-
productivity and product quality [36]. Sustainable machining focuses vironmental effect are impacted by the machining technology and pa-
on the triple bottom line: economic, environmental, and social aspects rameters. In order to reduce processing time and environmental effect,
[83]. Sustainable CNC machining operations can be optimized by con- it is necessary to optimize the cutting tool paths and machining settings.
sidering various parameters such as: Here are some tips for optimizing cutting tool paths in sustainable CNC
machining operations:
1. Material selection: The sustainability of the process is significantly
impacted by the material selection for machining operations. Steel 1. Using the right cutting tools: Choosing the right cutting tool is critical
and plastics are not chosen over environmentally friendly materials for optimizing the tool path. It is essential to select the right tool that
like titanium, brass, and aluminium. can handle the material being machined, the type of cut required,
2. Cutting parameters: The selection of appropriate cutting parameters and the surface finish required. Using the right tool can help reduce
such as cutting speed, feed rate, and depth of cut can significantly re- the number of passes needed and reduce tool wear, resulting in less
duce energy consumption and material waste, while also improving waste and longer tool life [96].
tool life and surface finish. The machining quality and effectiveness 2. High-Quality Cutting Tools: High-quality cutting tools can help re-
of heavy-duty CNC machine tools are directly impacted by machin- duce the amount of wear and tear on the machine, which can reduce
ing process parameters [84]. The optimal cutting speed depends on the amount of energy needed to operate it. This can also help reduce
the type of material being machined and the specific machining op- the amount of waste generated during the machining process [97].

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Fig. 2. The optimization of turning process for the sustainable machining [81].

3. Optimized cutting parameters: The cutting parameters such as the ergy consumption, tool selection, and waste reduction. By implementing
feed rate, spindle speed, and depth of cut, have a significant im- these strategies for optimizing cutting tool paths in CNC machining oper-
pact on the cutting tool path. Optimizing these parameters can help ations, it is possible to achieve sustainable and environmentally friendly
reduce tool wear, improve machining accuracy and efficiency, and machining processes.
minimize waste [98].
4. Optimized cutting path strategy: The cutting path strategy used in Process planning of CNC machining
the CNC machining process can significantly impact the sustainabil-
ity of the operation. Using the appropriate cutting path strategy, such Process planning for CNC machining in sustainable machining in-
as zigzag, spiral, or contour cutting, can help reduce material waste, volves designing a machining process that not only produces high-
improve machining accuracy and efficiency, and extend the life of quality parts but also minimizes the environmental impact, reduces
cutting tools [99]. waste, and optimizes resource utilization [103]. Process planning for
5. CAD/CAM Software: Using CAD/CAM software can optimize cutting CNC machining in sustainable machining involves optimizing the man-
tool paths by providing the simulation and optimization of the ma- ufacturing process to minimize environmental impacts while maintain-
chining process before it is actually performed. This can reduce the ing or even improving productivity and product quality [37,104]. An
amount of generated waste materials during the machining process integrated approach of process planning and cutting parameter opti-
and ensure that the tool is used in the most efficient way possible mization is recommended for energy-conscious CNC machining to lower
[100]. total energy consumption and balance machine workloads [105]. Fig. 6
6. Adaptive cutting operations: Adaptive cutting is an advanced CNC illustrates the integration of process planning and cutting parameter op-
machining technique that involves adjusting the cutting tool path timization [105].
based on real-time feedback from the machining process. This tech-
Energy efficiency improvement of CNC machining operations
nique can help optimize the tool path to achieve maximum material
removal with minimum tool wear, reducing waste and extending
Investigations on the energy used in machining processes are needed,
tool life [101].
not only to determine how it affects the environment but also to identify
7. High-Speed Machining Techniques: High-speed machining tech-
other phenomena that may occur. The energy characteristics of CNC ma-
niques, such as trochoidal milling, can help reduce the amount of
chining often vary significantly depending on the technique design and
time needed to complete a job, which can save energy and reduce
the diversity of operating processes. An analysis of recent writing focuses
waste.
on the energy demands shown for CNC machining. Other applications
8. Simulation software: Simulation software can help optimize the cut-
include the indirect monitoring of tool conditions through the measure-
ting tool path before starting the actual machining process. It can
ment of machine tool electrical power usage. Other applications include
simulate different cutting scenarios, allowing the operator to select
the indirect monitoring of tool conditions through the measurement of
the optimal path for a given material and cutting tool, reducing
machine tool electrical power usage [106]. This indirect measuring tech-
waste and improving accuracy [102].
nique has shown to be an effective, low-cost, versatile, and rapid way to
Overall, sustainable CNC machining operations and cutting tool path assess tool quality. For monitoring tool condition, this indirect measur-
optimization require careful consideration of material utilization, en- ing technique has shown to be a cheap, highly trustworthy, adaptable,

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Fig. 3. RUL-based strategy for improving cutting tool sustainability [90].

and rapid method [107]. Many studies have been conducted at the pro- ters and energy modeling throughout the machining process are known
cess control level to enhance the mechanics of tool-chip interaction and to be strong and efficient energy-saving techniques. Nevertheless, only
decrease the amount of energy used in machining. One of the possible 15–25 % of the total energy spent by the machine during the material
solutions is to use the machine tool energy-saving potential that was just removal process is really used for cutting when a machine tool is used to
mentioned. The difference between the energy used by the machine tool remove material [111]. The controller, fluid pump, fan, and other ancil-
and the actual energy required for material removal represents the to- lary devices are responsible for a portion of the machine’s overall energy
tal potential for energy savings in the CNC metal cutting process [108]. consumption. The remainder of the energy is used by other components
Multi-Objective optimization of CNC turning process parameters con- inside the machine. Potentially reducing the energy consumption for
sidering transient-steady state energy consumption is presented by Jia the same machining task during the planning and scheduling phases in-
et al. [109] to minimize energy consumption during machining opera- volves using smaller machine tools. Another planning-level method to
tions. Fig. 7 illustrates the use of the Taguchi technique and the response reduce energy consumption throughout the machining process is to min-
surface approach for parameter optimization [109]. imize the energy needed during the cutting period by choosing the best
The potential for energy savings in machine tools may be used in cutting settings [112]. Observations reveal that the decision made re-
a wide variety of ways. Monitoring energy use can help identify areas garding the process parameters affects the overall energy consumption
where energy consumption can be reduced. By optimizing energy use, of a machine tool and, therefore, its efficiency during a cutting opera-
CNC machining operations can become more sustainable and energy- tion [113]. Consequently, determining the ideal set of process variables
efficient [110]. Minimizing setup time can help reduce energy consump- to use when performing a certain cutting task may be reduced to noth-
tion and material waste. By optimizing the setup process, machines can ing more complicated than a mathematical optimisation problem. Here
be used more efficiently, reducing the need for additional setup time. are some tips for achieving this:
Reducing the number of tool changes can save time and energy. If mul-
tiple tools are needed, group them together so that they can be changed 1. Upgrade to more energy-efficient equipment: Newer CNC machines
at the same time. Also, selecting the right cutting tool for the material are often more energy-efficient than older ones. If your equipment is
being machined can reduce the amount of energy needed to cut the outdated, consider upgrading to more energy-efficient models that
material and extend the life of the tool. Optimization of cutting parame- use less power [114].

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Fig. 4. Flowchart of tool-path optimization considering carbon emissions [93].

2. Optimize cutting parameters: Optimizing cutting parameters can re- Metal chips and swarf recycling during CNC machining
duce the energy consumption of the machine. For example, reducing
cutting speed or feed rate can help save energy while still producing Metal swarf in metalworking refers to the metallic chips left over af-
high-quality parts. ter shaping the metal. Metal chips or swarf are the small pieces of metal
3. Use energy-efficient lighting: Replacing traditional lighting with LED that are generated during CNC machining processes, such as drilling,
lighting can reduce energy consumption in the shop. LED lights use milling, and turning [39]. These metal chips can accumulate quickly
less energy and last longer, which can result in lower energy costs and create a significant amount of waste if they are not managed prop-
and maintenance expenses [115]. erly. Many specialized machining processes, including as boring, grind-
4. Implement a preventive maintenance program: Proper maintenance ing, grooving, knurling, reaming, sawing, slotting, and tapping, are used
of equipment can improve its energy efficiency. Implementing a to create swarf [120]. Recycling metal chips or swarf produced during
preventive maintenance program can help keep machines running CNC machining is a sustainable and environmentally responsible prac-
smoothly, reducing the amount of energy they consume [116]. tice. It helps reduce waste, save resources, and can even generate some
5. Use renewable energy sources: To help the store meet its energy de- financial returns for manufacturing operations. Here are some steps and
mands, think about employing sustainable energy sources like solar considerations for recycling metal chips or swarf:
or wind energy. This may lessen the need for fossil fuels and cut
greenhouse gas emissions [117]. 1. Collection and segregation: Collect the metal chips and swarf gener-
6. Implement energy-saving practices: Encourage energy-saving prac- ated during CNC machining in containers or bins. Ensure that they
tices among employees, such as turning off machines when they are are clean and free from contaminants like coolant or oil. Segregate
not in use, using power-saving modes, and ensuring that equipment different types of metals (e.g., aluminium, steel, brass) as they can
is properly maintained [118]. often be recycled separately.
7. Supply chain management: Ensuring that the supply chain is sustain- 2. Fluid removal: Depending on the machining process, metal chips can
able can also help reduce the energy required for CNC machining. be coated with cutting fluids or coolants. Remove these fluids before
This can be achieved by sourcing materials from sustainable sup- recycling. Centrifuges, chip wringers, or other equipment designed
pliers, reducing transportation distances, and optimizing inventory can be used for fluid removal [121].
management [119]. 3. Storage and Transportation: Store the segregated and cleaned metal
By implementing these strategies, CNC machining operations can be- chips in appropriate containers to prevent contamination. Arrange
come more sustainable and reduce their energy consumption, which can transportation to take the metal chips to a recycling facility. Lo-
help save money and protect the environment cal scrap yards or metal recycling centers are common options.

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Fig. 5. Hole machining optimization to minimize energy usage [94].

Ensure that the waste is properly secured during transport to pre- Environmental friendly cutting fluids and cooling techniques
vent spillage or accidents.
4. Find a recycling facility: Research local recycling facilities that ac- In order to counteract the consequences of overheating during ma-
cept metal chips and swarf. Some facilities may specialize in recy- chining operations, cutting fluids are widely employed in metal machin-
cling metal waste from machining processes. Check their require- ing processes. By boosting machining efficiency and extending tool life,
ments for accepting materials. it reduces machining expenses. CNC machining operations can have a
5. Clean and separate: To facilitate recycling, clean the collected metal significant impact on the environment due to the use of cutting fluids
chips and swarf to remove contaminants such as coolants, oils, or and cooling techniques that can be harmful to the ecosystem [124]. As
other residues. You may need specialized equipment for this process the vapour and mist created during machining procedures are harmful
[122]. to the operator, there are tight regulations to manage them. Direct con-
6. Environmental Considerations: Some materials used in CNC machin- tact with cutting fluids is to blame for the prevalence of skin cancer
ing can be hazardous. It is essential to follow local regulations and disorders [125]. Strict environmental regulations are needed to spec-
safety guidelines for handling and recycling these materials [123]. ify how used cutting fluids should be disposed of or recycled in order
7. Sustainability benefits: Recycling metal chips and swarf conserves to protect the environment. More costs are required for the removal
natural resources, reduces energy consumption, and lowers green- and recycling processes for various cutting fluid kinds [126]. The use
house gas emissions compared to producing metal from raw materi- of biodegradable cutting fluids during the machining process is the ap-
als. It also minimizes the amount of waste sent to landfills [41]. proach for sustainable machining in a particular industrial organization.
Cutting fluids that are biodegradable or ecologically friendly prevent the
Recycling metal chips and swarf is not only an eco-friendly practice
release of dangerous gases during the machining process and protect
but can also be financially beneficial for your manufacturing operation.
the operator’s skin. Having a backup strategy is helpful in case some-
It contributes to a more sustainable and responsible approach to CNC
thing goes wrong [127]. For the safe use of environmentally friendly
machining and metalworking.

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Fig. 6. Application of process planning in cutting parameter optimization [105].

cutting fluids, several strategies have been put into place. By reducing 4. Optimize toolpath and tool selection: Proper toolpath and tool se-
heat and friction, using a high-quality coolant can help the cutting tool lection can reduce the amount of heat generated during machining,
last longer and use less energy. The following are the results of the sur- which can reduce the need for cooling and cutting fluids.
vey. The thermal and tribological properties of vegetable oil-based ma- 5. High-pressure coolant systems: High-pressure coolant systems can
chining fluids with nanoparticle enhancement are much superior than reduce the amount of coolant used in machining operations while in-
those of traditional vegetable oil-based machining fluids. In terms of creasing efficiency. These systems use a high-pressure jet of coolant
energy efficiency, carbon emissions, and machining parameters, Fig. 8 to direct the coolant directly to the cutting zone, reducing the
shows sustainable milling of Ti-6Al-4V [38]. amount of coolant needed. This technique can reduce fluid usage
Here are some cooling methods and cutting fluids that are environ- by up to 90 % [129].
mentally friendly for sustainable CNC machining operations: 6. Dry machining: While cutting fluids are essential for certain machin-
ing operations, excessive use can lead to waste and unnecessary pol-
1. Vegetable-based cutting fluids: Vegetable-based cutting fluids are a lution. Try to use only the amount of cutting fluid necessary to per-
sustainable alternative to traditional mineral oil-based cutting flu- form the job. Dry machining is a technique that eliminates the need
ids. They are made from natural ingredients such as soybean oil and for coolant altogether. It involves using specialized cutting tools that
canola oil, making them biodegradable and non-toxic [128]. generate minimal heat and friction, reducing the need for coolant
2. Recycle cutting fluids: When possible, try to recycle cutting fluids. [130].
This can be done by filtering and treating the fluids, which can ex- 7. Air cooling: Air cooling is a technique that uses compressed air to
tend their useful life and reduce waste. cool the workpiece and cutting tool. It is an effective method for low
3. Use mist collection systems: Mist collection systems can capture mist to medium speed machining operations that generate minimal heat.
and smoke generated during machining and prevent it from polluting 8. Closed-loop cooling systems: Closed-loop cooling systems recycle
the air. These systems can be combined with cutting fluid recycling coolant, reducing the amount of coolant needed and minimizing
systems to further reduce waste [36]. waste [131].

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Fig. 7. Taguchi and response surface methods are used in parameter optimization [109].

Fig. 8. Ti-6Al-4V sustainable milling improving energy effectiveness, carbon emissions, and machining properties [38].

9. Biodegradable coolant additives: Biodegradable coolant additives Fig. 10 illustrates a quantitative method for analyzing the carbon
can be added to traditional cutting fluids to improve their biodegrad- emissions of CNC-based machining equipment [134].
ability and reduce their environmental impact. There are several ways to reduce carbon emissions and improve sus-
tainability in CNC machining operations. Here are a few suggestions:
By implementing these sustainable cutting fluids and cooling tech-
niques, CNC machining operations can reduce their negative impact on 1. Energy-efficient equipment: Use energy-efficient CNC machines and
the environment while maintaining high levels of efficiency and produc- equipment, which consume less energy and emit fewer carbon emis-
tivity. sions [135].
2. Renewable energy: Install solar panels, wind turbines, or other re-
Carbon emissions savings in CNC machining operations newable energy sources to power CNC machines and equipment
[136].
CNC machining operations can contribute to carbon emissions 3. Material selection: Choose sustainable and environmentally friendly
through energy consumption and waste generation. Reducing carbon materials, such as recycled or biodegradable materials, that produce
emissions in sustainable CNC machining not only benefits the environ- less waste and lower carbon emissions during production.
ment but can also lead to cost savings and improved operational effi- 4. Waste reduction: Implement waste reduction strategies such as recy-
ciency [132]. In this approach, energy consumption and carbon emis- cling, reusing, or repurposing materials to reduce waste and carbon
sion levels should be reduced while industrial processes are streamlined emissions [137].
[133]. Fig. 9 displays the sources of carbon emissions in the industrial 5. Process optimization: Optimize CNC machining processes to mini-
industry [38]. mize material waste and energy consumption. This can be achieved

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Fig. 9. Sources of carbon emissions in the manufacturing sector [38].

Fig. 10. Analyzing carbon emissions from CNC-based machining equipment quantitatively [134].

through toolpath optimization, reducing machining time, and using sumption, and material usage [140]. By using virtual simulations, oper-
cutting tools with longer lifetimes [138]. ators can test different machining strategies and tool paths before they
6. Transportation optimization: Optimize transportation logistics to re- are implemented, allowing them to identify and correct potential issues
duce carbon emissions from transportation of raw materials, finished during production process [141]. Before to assigning work to the shop
products, and waste [139]. floor, machining simulation makes sure that the process plan and NC
By implementing these measures, CNC machining operations can re- program are finished and accurate. CNC simulation and analysis can
duce their carbon footprint and contribute to a more sustainable future. predict and prevent collisions during machining operations in order to
enhance safety of CNC machining operations [142]. This is because the
Virtual simulation and analysis of CNC machining operations technology has the capacity to simulate actual working conditions and
recognize possible collisions or other problems which can be happen
Virtual simulation and analysis of CNC machining operations can during the machining process [143]. Before beginning the real machin-
help to optimize the machining process and reduce waste, energy con- ing process, users and CNC design engineers can test a wide range of

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performance-related characteristics of CNC machine tools with a Carte- 5. Green Supply Chain: A sustainable CNC machining operation re-
sian configuration using the sophisticated virtual CNC module [144]. quires a green supply chain. This means working with suppliers who
The simulation software can also be used to optimize the cutting tool- use eco-friendly materials and processes, and who have a strong com-
path for a given part in order to minimize the amount of material that mitment to sustainability.
needs to be removed [145]. Another approach is to use virtual simu- 6. Reusable Tooling: By Investing in high-quality, durable cutting tools
lation and analysis to evaluate the environmental impact of the ma- that can be sharpened or reconditioned rather than disposed of after
chining process. This can include analyzing the energy consumption, one use, sustainable CNC machining operations can be implemented.
Co emissions, and waste materials generated during the CNC machin- 7. Monitoring and Reporting: Sustainable CNC machining requires con-
ing processes [146]. This information can then be used to identify areas tinuous monitoring and reporting of the environmental impact of the
where sustainable CNC machining can be implemented in order to re- machining operation. This will enable the identification of areas for
duce the environmental impact of the process. The engineer can validate improvement and the implementation of strategies to minimize the
the whole NC process once the tool path has been optimized and con- environmental impact of the operation.
firmed by utilizing a model of the machining center that includes the 8. Coolant Management: Proper coolant management is essential for
tool changer and material handling equipment. As a result, trial-and- both machine performance and sustainability. Recycling and filter-
error cuts can be minimized using virtual simulation to save money and ing coolants can reduce waste and minimize environmental contam-
time during CNC machining operations [147]. The major goals of em- ination.
ploying a virtual machining systems during machining process are to 9. Education and Training: Training the operators and staff of CNC ma-
maximize machine utilization, improve product quality, save time and chine tools regarding the sustainable machining practices and best
money, and minimize costly machine tool accidents [148]. Moreover, it environmental practices can decrease the environmental impacts of
can help operators to optimize their cutting parameters, such as cutting machining operations.
speed, feed rate, and depth of cut, to minimize energy consumption and
By following these steps, CNC machining operations can be made
extend tool life [149]. By analyzing the results of virtual simulations,
more sustainable, resulting in a reduced environmental impact and im-
operators can identify opportunities to reduce waste and improve sus-
proved efficiency.
tainability. For example, they may be able to reduce the amount of ma-
terial that is removed during the machining process, or optimize the use
Future research directions
of cutting fluids to minimize their environmental impact [43]. Overall,
virtual simulation and analysis of CNC machining operations can help to
Sustainable CNC machining operations are becoming increasingly
improve the efficiency and sustainability of machining processes, while
important as companies seek to reduce their environmental impact
also reducing costs and improving product quality. It can be a valuable
while maintaining high levels of productivity and profitability. A
tool for implementing sustainable CNC machining operations in order
promising application area is the application research of control tech-
to reduce waste, improve efficiency, and minimize the environmental
niques in CAPP and NC code generation to accomplish energy-efficient
impact of the process.
control of CNC machine machines. Also, a number of parameters, such
as inertia, warming, sequential setups, or safety concerns, impact the
Conclusion choice and execution of the control method, although the significance
of each component varies. Sustainable machining processes may be car-
CNC machining is a widely used manufacturing process that auto- ried out using a variety of methods and strategies. Several researchers
mates the production of precision components, often used in industries discovered alternatives to traditional machining techniques to reach
such as aerospace, automotive, and medical devices. Sustainable CNC sustainable objectives. It will improve worker health, cut down on
machining operations involve the use of efficient and eco-friendly pro- machining expenses, and lessen the environmental effect. The meth-
cesses in the production of precision components. Sustainable CNC ma- ods/techniques include cryogenic cooling, dry cutting, high-pressure
chining operations not only benefit the environment but can also result coolant, biodegradable lubricants, and minimal quantity lubrication
in cost savings and improved competitiveness in a world increasingly (MQL). The hybrid nano cutting fluids can be employed in a variety
focused on sustainability. Here are some steps for sustainable CNC ma- of machining processes, and their effects can be researched. Also, it is
chining process planning: possible to investigate how the performance of the machining fluids is
affected by the size and shape of the nanoparticles in the base fluids.
1. Design for Sustainability: The first step in sustainable CNC machin-
Here are some potential research areas that could help advance sustain-
ing process planning is to design for sustainability. This means tak-
able CNC machining operations:
ing into account the environmental impact of the product, including
its energy consumption, material selection, and end-of-life disposal. 1. Material selection: Research could focus on identifying more sus-
The design should aim to minimize material waste and energy con- tainable materials for CNC machining, such as recycled or bio-based
sumption while maximizing the use of recycled materials. materials, that can replace traditional materials that are less environ-
2. Material Selection: The selection of materials is critical in sustain- mentally friendly. When possible, choose sustainable materials that
able CNC machining. Materials with a low environmental impact, are easy to recycle or biodegradable. This can considerably lessen
such as recycled materials, should be used wherever possible. Addi- the machining process’ negative environmental effects.
tionally, it is important to select materials that can be easily recycled 2. Energy efficiency: Studies could examine ways to improve the energy
or disposed of at the end of the product life cycle. efficiency of CNC machines, such as by optimizing their operating
3. Energy-efficient Machining: CNC machining operations consume a parameters, using more efficient motors and drives, and implement-
lot of energy. Therefore, it is important to use energy-efficient ma- ing energy-saving technologies.
chining methods to reduce the amount of energy used for machin- 3. Waste reduction: Research could focus on reducing waste in CNC
ing. This can be achieved by using efficient cutting tools, optimizing machining operations, such as by optimizing cutting parameters to
cutting parameters, and using coolant systems that reduce energy minimize scrap and by developing new recycling technologies for
consumption. materials such as metal chips and coolant.
4. Waste Reduction: The production of precision components often gen- 4. Life cycle assessment: A thorough life cycle assessment (LCA) could
erates a lot of waste. Therefore, sustainable CNC machining process be performed to evaluate the environmental impact of CNC machin-
planning should include waste reduction strategies, such as recycling ing operations from raw material extraction to end-of-life disposal,
chips and coolant fluids. in order to identify areas where improvements can be made.

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