The benefits of hardturning include reduced setup costs; shorter tool change times; improved squareness by virtue of the ability to machine cylinder I.D., O.D. and face in one chucking; low energy consumption and elimination of the need to handle grinding sludge and waste fluid. Hardturning has typically been used as a replacement for grinding, in the processing of fitting surfaces or clad surfaces, and other such relatively straightforward applications not requiring sliding. In recent years, however, due to advances in servo and other machine technology, and tool material improvements (CBN, ceramics), hardturning has entered the realm of finishing curved and complex shaped surfaces that have sliding and rolling contacts. This paper will present the machine characteristics developed to meet the ever increasing demand for hardturning process accuracy, and introduce each of the factors which ultimately affected the design of machine components, providing examples where appropriate.

The enhancement of machine tool accuracy has a direct effect on part quality. The state-of-the-art technology for this is the compensation method based on the measurement of the machine tool error parameters. This technology, however, has two major drawbacks: (i) it requires long calibration time (ii) for many applications this complicated compensation process is over specified because the parts have limited features and dimensions, and hence the compensation of whole working space is not needed. Furthermore, if the compensation of machining systems for high-volume production is considered, then the fast error measurement and subsequent rapid compensation becomes critical, and the current technology obviously cannot meet these requirements. An alternative method that we propose in this paper is to measure the part rather than the machine, and compensate the machine tools according to these measurements. This proposed methodology requires the modeling of the relationship between the machine tool errors and the part errors, which is called here “machine-part error mapping model”. The modeling enables to identify the individual machine tool error parameters that contribute on the part error. In order to use this model to compensate for the machine tool error, test part should be carefully developed. In this paper, several rules in the design of test part are presented first, and as an example, the test part for the flatness error compensation of horizontal machining center was designed. From the measurement result of the machined test part, each error source parameters that are responsible for the chosen machining process were identified, and compensated by using the real time compensation system.

The present work reports macroscopic thermal mechanical and in-situ neutron diffraction measurements from a 14.4 volume percent, 50.7 at% Ni-Ti fiber actuated 6082-T4 aluminum matrix composite and 6082-T4 homogeneous aluminum control material subjected to a room temperature 5% tensile elongation, and subsequent room temperature to 120 deg. C unconstrained heating process. During the unconstrained room temperature to 120 deg. C heating process, the composite exhibited a 2.2%, nonlinear thermal contraction, while the homogeneous control exhibited the expected linear thermal expansion. The composite thermal compression was clearly the result of a powerful shape memory response in the actuating NiTi fibers. During a subsequent temperature hold at 120 deg. C the composite exhibited an external stress free compressive creep response. The compressive creep behavior was the result of matrix creep under the large compressive stresses imposed by the shape memory active NiTi fibers. In summary, the experimental composite has demonstrated a new form of large deformation self thermal-plastic response which may be used in thermally controlled adaptive machine parts and structures.

Whilst extensive work has been done on fault detection in bearings using sound, very little has been accomplished with other machine components and machinery partly due to the scarcity of datasets. The recent release of the Malfunctioning Industrial Machine Investigation and Inspection (MIMII) dataset opens the opportunity for research into malfunctioning machines like pumps, fans, slide rails, and valves. In this paper, we compare common features from audio recordings to investigate which best support the classification of malfunctioning pumps. We evaluate our results using the Area Under the Curve (AUC) as a performance metric and determine that the log mel spectrum is a very useful feature, at least for this dataset, but that other features can enhance detection performance when ambient noise is present (improving AUC from 0.88 to 0.94 in one case). Also, we find that mel Frequency Cepstral Coefficients (MFCC) perform substantially poorer as features than a sampled mel spectrogram.

Finite element (FE) assisted numerical modeling approach is known as a popular approach to predict the machining performance of different machining operations. Tapping operation is a well-known manufacturing process that is used to cut threads efficiently. In the automotive and aerospace applications, precisely machined tapped holes are required in the small size deep holes. Tapping process creates thread in the hole and make it ready for fastening with other mating components. Tapping operation is considered as one of the most complex machining operations due to the presence of multi-flutes and multi-land involvement between the workpiece and cutter materials. The outcome of the tapping process results in the generation of threads and accepted as one of the most commonly employed in fastening methods for the joining of different machine components. Literature revealed that tapping process has been very rarely investigated using computational modeling approaches, as most of the available studies are experimental in nature. The experimental work for tapping operation can be very time and cost consuming because of the expensive fabrication of the cutting tools. It has also been observed experimentally that minor change in the threading profiles can generate significant difference in the cutting torque. A possible solution is to analyse the whole tapping operation using finite element (FE) assisted numerical simulation. Similarly, there will be limitation towards experiments if the workpiece material is expensive and difficult to cut. It is a common observation in metal cutting industry that most of the times cutting tap results in breakage when exposed to the higher magnitude of torque. The current study is aimed on the finite element based computational investigations on the tapping process using Ti6Al4V as a workpiece material. High hot hardness and low thermal conductivity of the Ti6Al4V also plays a significant role towards the poor machining performance of the threading tool. Ti6Al4V is most commonly employed in the engineering applications where high strength to weight ratio and ability of operate at higher temperatures is required. Ti6Al4V is mainly utilized in the automotive, aerospace, biomedical and petrochemical industries. It has been identified that tapping operation is very rarely studied machining operation in the metal cutting scientific community. Different tapping process conditions were investigated computationally using finite element (FE) approach and as a result cutting forces, torques and power consumed were observed. The study provides a useful understanding towards the tapping process mechanics with respect to different cutting parameters.

High speed rotating machineries usually operate under severe conditions and enormous loadings and thus, are susceptible to several problems. One such problem that has caught the attention in recent decades is known as High Cycle Fatigue. More than 60 percent of rotating machinery failures has been attributed to this High cycle Fatigue. Along with High Cycle Fatigue, Vibration, an inherent phenomenon in machineries, also share its part in failure of rotating machineries. Rotating machinery components suffer from high amplitude vibrations when they pass through resonance. Stresses are developed as a result of these vibrations and fatigue in mechanical structures, providing a conducive environment for the development of cracks at Surface. When these surface cracks reach critical size, crack nucleation starts, which ultimately leads to catastrophic failures. So, in order to avoid the disastrous consequences, damping is needed. Damping keeps material’s integrity in case of impact forces, stresses due to thermal shocks in turbo machinery and earth quakes in huge structures. Thin layer of magneto elastic coating can be applied on substrate surface that acts as first line of defense. Large number of coating Processes are available around the globe. The optimized combination of coating material, substrate material and coating technique according to specific application is necessary. These coatings have the capability to combat the phenomenon of oxidation, wear and fatigue acting as a barrier between substrate and hostile environments. Further, they enhance the damping characteristics, and thus allows the highspeed rotating machinery to reach its operational speed without any failure at resonance. In this way, they not only enhance the performance of components in aggressive environments, but also improve the life cycle, saving assets of millions of dollars’ worth. This research is an endeavor to experimentally investigate effect of magneto mechanical coating on damping of AISI 321 Stainless steel. AISI 321 was selected as base material because of its wide applications in engine components of gas turbines, heat exchangers and in different chemical industries. Two types of Air plasma sprayed magneto-mechanical powder (NiAl & CoNiCrAlY) were coated on base material and thickness was maintained up to 250μm in both the cases. Experiments were designed and performed on cantilever beam specimens for dynamic response measurement. Dynamic response of the system was measured to investigate the modal parameters of natural frequencies, damping ratio and time of vibration decay. For damping ratio, vibration analyzer mode was adjusted in time domain and beam was excited by using a hammer. Vibration analyzer showed the vibration decay as a function of time. Logarithmic decrement method was used to calculate the damping ratio in both cases. Dynamic response of all the three cases (NiAl coating, CoNiCrAlY and uncoated AISI321) were compared. Results were very reassuring and showed a significant improvement in damping characteristics.

High speed rotating machineries usually operate under severe conditions and enormous loadings and thus, are susceptible to several problems. One such problem that has caught the attention in recent decades is known as High Cycle Fatigue. More than 60 percent of rotating machinery failures has been attributed to this High cycle Fatigue. Along with High Cycle Fatigue, Vibration, an inherent phenomenon in machineries, also share its part in failure of rotating machineries. Rotating machinery components suffer from high amplitude vibrations when they pass through resonance. Stresses are developed as a result of these vibrations and fatigue in mechanical structures, providing a conducive environment for the development of cracks at Surface. When these surface cracks reach critical size, crack nucleation starts, which ultimately leads to catastrophic failures. So, in order to avoid the disastrous consequences, damping is needed. Damping keeps material’s integrity in case of impact forces, stresses due to thermal shocks in turbo machinery and earth quakes in huge structures. Thin layer of magneto elastic coating can be applied on substrate surface that acts as first line of defense. Large number of coating Processes are available around the globe. The optimized combination of coating material, substrate material and coating technique according to specific application is necessary. These coatings have the capability to combat the phenomenon of oxidation, wear and fatigue acting as a barrier between substrate and hostile environments. Further, they enhance the damping characteristics, and thus allows the high-speed rotating machinery to reach its operational speed without any failure at resonance. In this way, they not only enhance the performance of components in aggressive environments, but also improve the life cycle, saving assets of millions of dollars’ worth. This research is an endeavor to experimentally investigate effect of magneto mechanical coating on damping of AISI 321 Stainless steel. AISI 321 was selected as base material because of its wide applications in engine components of gas turbines, heat exchangers and in different chemical industries. Two types of Air plasma sprayed magneto-mechanical powder (NiAl & CoNiCrAlY) were coated on base material and thickness was maintained up to 250μm in both the cases. Experiments were designed and performed on cantilever beam specimens for dynamic response measurement. Dynamic response of the system was measured to investigate the modal parameters of natural frequencies, damping ratio and time of vibration decay. For damping ratio, vibration analyzer mode was adjusted in time domain and beam was excited by using a hammer. Vibration analyzer showed the vibration decay as a function of time. Logarithmic decrement method was used to calculate the damping ratio in both cases. Dynamic response of all the three cases (NiAl coating, CoNiCrAlY and uncoated AISI321) were compared. Results were very reassuring and showed a significant improvement in damping characteristics.

The use of cutting tool systems with a high slenderness ratio is encountered in the machining of deep cavities in the mechanical engineering industry, especially in the manufacturing of tools and dies. Cutting tool systems with a large slenderness ratio, owing to their dynamic compliance, are prone to vibrations during machining processes. These vibrations affect the quality of the machining process and the life of machine components. Integration of a vibration absorber in the cutting tool system helps in the reduction of machining vibrations. The reduction in vibrations is due to a shift in the resonance frequency of the modified system. This experimental study presents the identification of design possibilities of a vibration absorber for integration in the cutting tool system. The mass and geometry of the vibration absorber are varied and its integration in the milling chuck is explored. Firstly, experimental modal analysis is conducted to determine the effects of the dynamic vibration absorber on the frequency response function of the modified cutting tool system. Secondly, the effects of the dynamic vibration absorber on the machining process for a range of technology parameters are illustrated. During the machining process, the cutting forces are measured using a three-component dynamometer in time domain. Finally, the results are evaluated based on process quality, i.e. surface roughness and analysis of cutting force signal in the frequency domain. This study provides an understanding of the relationship between the mass and the geometry of the vibration absorber integrated in the cutting tool system and their influence on process stability.

The friction behavior of rolling ball machine components like linear ball bearings is very important to their functionality. For instance, differences in linear velocity of balls induces ball-to-ball contact in certain circumstances, resulting in significant increases and variations in friction. In this paper, an improved analytical formula for determining the linear velocity of balls in four-point-contact linear ball bearings is derived as a function of contact angle deviations and contact forces. The analytical formula is validated against a comprehensive friction model in the literature and shown to be in good agreement, while an oversimplified analytical model proposed by the authors in prior work is shown to be inaccurate. A case study is presented where insights gained from the derived analytical formula are used to mitigate velocity difference of balls in a linear ball bearing which otherwise would experience ball-to-ball contact.

The undergraduate course, Design of Machine Elements has been offered by the University of Connecticut’s Mechanical Engineering Department for many years. It has been one of the most difficult courses for students to follow and understand, and also for the faculty to teach. A strong basic knowledge of mathematics, theoretical mechanics and the mechanics of materials is required for students to take this mandatory course and to fully follow its contents. To understand entirely the concepts of Design of Machine Elements, students should be acquainted with the history of the strength of materials. Being aware of the importance of such a course the ME faculty has worked to establish outstanding structural engineering teaching and research methods, and to create a departmental nucleus of intensive development of engineering mechanics research and development. The efforts described in this paper have facilitated the teaching and learning of the mechanics of materials and consequently the Design of Machine Elements as well. To accomplish these in both teaching and practical problem solving the instructor must use the unconventional approaches and students must put a great deal of effort into learning the material. It is important for students to have a general knowledge of mathematics and theoretical mechanics, but as this is a foundation of the course, the instructor should review and clarify the specific assumptions of engineering mechanics and strength of materials. One of the pedagogical challenges to be overcome, which is faced by both instructors and students, has always been to connecting the basic theorems and application procedures of engineering mechanics to their practical use in designing machine elements and in calculating static and dynamic stresses and deformations. The concept of avoiding stress concentrations by properly designing the shapes of machine frames and parts should also be emphasized. Transforming plane stresses and deformations into three-dimensional representations and calculations should also be considered. Since machine elements are usually in motion, a dynamic approach to stress and deflection analysis is important as well. After introducing the analysis of dynamic stresses and deformations, the instructor should cover the concept of fatigue, which is the next crucial step. The instructors’ approaches and the unconventional methods they use to familiarize students with such complicated concepts are discussed in this paper. An analysis of representations of stresses and deformations and fatigue analyses of different machine elements are also considered. This paper connects to some approaches previously presented in earlier papers as well as in courses, books and discussions by outstanding engineering mechanics theoreticians, including UConn faculty, especially Dr. Roman Solecki. The paper concludes by recommending effective teaching approaches to complicated machine design concepts and summarizing the lessons learned. This paper is a companion piece to the IMECE 2015 50776 [1].

This paper discusses the results of a literature search on implementing novel approaches to teaching engineering design as well as the need for teaching Systems Engineering (SE) at an undergraduate level. In addition, the paper presents the results and lessons learned by assigning a capstone project requiring students to develop a conveyor system using the 8-phase SE process and a project based collaborative design methodology. The instructor teaches the fundamentals of systems engineering, the concept of synthesis, and the basics of trade-off studies. Students learn how to use functional modeling and the proper use of a functional flow block diagram to transform design requirements into failure modes. Students perform traditional failure mode calculations, using a strength-resistance approach, on machine components such as shafts, bearings, gears, belts, chains, keyways, splines, clutches, springs, brakes, and bolts for the conveyor system’s transmission. The instructor assigns a conveyor system and its systems requirements and students must demonstrate their understanding of the SE process as well as being able to perform design calculations on various machine components. The students demonstrate their understanding of SE and failure modes by taking part in design reviews throughout the semester and a final engineering report.

This project describes the collaboration of two instructors, one from the mechanical engineering department and one from the mathematics department with a group of mechanical engineering students to build and analyze a new type of transportation transmission. Current transmissions have torque limitations when working at various vehicle loading conditions. The ideal vehicle transmission is a continuously variable transmission that delivers optimum torque at any loading condition. The motivation for this research project is to design a new transmission that would increase the number of gear ratios using a chain element, and consequentially, increasing the number of available torques to achieve better overall vehicle performance. The new transmission consists of two planetary gears systems linked by a chain. It includes multiple inputs and outputs with the possibility of using one of the outputs to drive other engine components. The system is currently investigated for all possible gear ratios and usable torque configurations. The gear ratios are determined using Willis’s formula for planetary gear systems. All possible gear combinations are investigated and their gear ratios mathematically determined. A prototype was designed and built. It is being automatized, currently.

Hollowness of loaded members has been investigated using rings and square plates with central hole under normal compressive loads. The objective is to define the relative size of the central hole or optimum hollowness that will not compromise the load carrying capability of the rings and plates. Hollowness is thus defined as the volume percentage of measurable void in load carrying member. The work presented here uses finite element analysis to plot the radial and transverse stresses of a ring and a square plate with central hole versus the radius the hole or hollowness. The observations from the numerical analysis are further confirmed with experimental verification using strain gages. Seven rings and seven plates are normally loaded between two plates while the radial and transverse strains are measured. The derived stress are plotted with respect to hollowness. The plots show a moderate increase in stresses up to about 35% to 40% hollowness in both finite element and experimental results. Above these values, which represent the optimum hollowness, the stresses increase along a steep curve. These results indicate that some load carrying or transmitting machine components can be fabricated with measurable voids leveraging recent advances in Additive Manufacturing.

Experimental estimation of acurate material properties are key elements to the design of machine components and structures. In general, the elastic properties were determined using uniaxial tensile tests regardless of the final shape of the product including pipes, which exhibit different elastic properties in the longitudinal and tangential directions due to their manufacturing process. Several attempts have been made to estimate the mechanical properties of pipes along their longitudinal directions including ASTM D2290 and exhibited inconsistent results; thereby, calling for further design and analysis. This paper, therefore, presents various design alternatives to the ring hoop tensile test adopted in the ASTM D2290 standard through finite element modeling. The design optimization consisted of varying the ring width, dogbone width, dogbone gauge length, and the spacing between the two D-blocks to obtain the optimum values of the varying parameters that provide uniform normal stress across the cross-sectional area of the dogbone and more representative mechanical response. Finite element results revealed that the proposed dogbone sample design has an optimum length to width ratio of 4 with an orientation angle between 75° to 105° with respect to the horizontal axis. The proposed model was compared to adopted test methods such as ASTM D2290 and resulted in comparable stress contours uniformity across the dogbone gauge length but different contact pressure values. it was also found that the contact pressure for the ASTM ring hoop tensile test is higher than that for the proposed model by 22%.

Typically, the design of machine parts is based on the dimensional and form tolerances and fragmentally on the surface roughness parameters (predominantly roughness average Ra). Despite the range of available 3D surface quality parameters, and the modern equipment to accurately measure them, design and quality professionals continue to specify surface finish based solely on the value of Ra. There are many reasons that contribute to this tendency: average roughness remains so easy to calculate, it is well understood, and vast amount of published literature explains it, and historical part data is based upon it. The same outlook trails in undergraduate education and their textbooks. It has been seen that Ra, typically, proves too general to describe surface’s true functional nature. Additionally, the push for complex geometry, coupled with tight tolerances, has reinforced the need to maintain increased process control along with improved surface finish. In turn, the surface finish over the entire area, not just the 2D parameters, tends to dictate the performance and reliability of the component. This article explores how these multitudes of 2D and 3D surface quality parameters are to be understood in the design and development of high performance surfaces, and the strong need for them to be incorporated into undergraduate engineering curriculum, and be taught as an improved toolkit to the aspiring engineers, process engineers and quality control professionals.

Four-point contact between ball and raceways is common in machine elements like ball bearings and ball screws. The ideal four-point-contact machine element is designed with pure rolling (i.e., no sliding at contact points) to minimize friction. However, this ideal may not always be achieved, leading to sliding and higher frictional forces. In this paper, a simplified analytical model for rolling/sliding behavior and friction in four-point contact is developed, based on Coulomb friction model and rigid body assumption. It is found that pure rolling is only possible when the contact-point geometry satisfies a certain relationship. When pure rolling condition fails to hold, the sliding contact point(s) can be determined analytically as a function of contact forces and contact angles. Case studies are presented to demonstrate how the proposed model could elucidate the roles of misalignments, manufacturing errors and loading conditions on rolling/sliding behavior and friction.

In this article a GHG and energy analysis for the plastic injection process of an ABS medium sized injected part carried out in a hybrid injection molding machine is reported. A power consumption process pattern for an ABS medium-size part is defined as well as the energy usage of components, the energy used for the injection process is calculated for the injection cycle and for the process setup. The reported study includes a hybrid machine analysis working under an electric network that relies mainly on thermoelectric energy generation. The GHG emissions assessment was estimated using the 2015 emission factor applied for Mexico. The results provide new experimental data for ABS plastic injected parts in hybrid injection machines. This paper describes the outcomes of a GHG emissions and energy assessment for an ABS medium-sized injected part carried out in a HIMM at UNAM. The approach followed by the authors in this assessment was aimed at providing information about the energy usage and GHG emissions for the process and the part. The main contribution of this paper is the insight related to energy usage indicators in the process, the energy usage and the GHG emissions within components. The product used as a case study and the results of its GHG emissions and energy assessment are presented.

The Manufacturing Automation course in the Mechanical Engineering program at the University of Connecticut (UConn) was one of the most popular courses in the ME curriculum. The students’ benefits from the course were already described in the companion paper [1]. In this paper the advantages of prototyping and part production through Subtractive Manufacturing (SM) and Additive Manufacturing (AM) are described. The paper discusses parts fabrication done as subtractive and additive manufacturing operations. This was done in the scope of the UConn Engineering i.e. in the ME and MEM programs where Manufacturing Automation and Senior Design courses are taught. Such operations were possible thanks to the equipment available at UConn School of Engineering and thanks to the cooperation with the creator of the Mastercam software - CNC Software Inc and aircraft engines and equipment manufacturer - Pratt & Whitney of East Hartford. The integration of design and manufacturing in the course was done through putting together the operations of conceptual design, geometric design and modeling of the parts designed during the course. The models of parts done by AM were created using 3D printing in ME Laboratory out of acrylonitrile butadiene styrene and different kinds of plastic and in PW/UConn laboratory using laser and electron beam AM machines. To demonstrate further integration of design and machining automation, the students were introduced to complicated problems of surfaces crossing, connections of surfaces and edges of cross sections of the tops and valleys. Thanks to the support and cooperation of the CNC Software, Inc., it was possible to show the students how to cut complicated surfaces on different computer numerically controlled (CNC) machines that ranged from three to nine degrees of freedom specifically designed for accurate and repeatable metal working. In addition, the additive manufacturing (AM) capabilities were introduced in the course thanks to the support of Pratt & Whitney/UConn Additive Manufacturing Laboratory located on the UConn campus. The AM machines are Arcam and laser machines that use electron and laser beams to meld titanium powder. The fabricated parts of high strengths are useful as rapid prototypes or in some cases as substitution parts in an existing mechanical systems. Thanks to the UConn Engineering program and support of the corporations: CNC Software, Inc. and P&W, students were introduced to the spectrum of modern Rapid Prototyping and part sintering operations going through subtractive and additive manufacturing. The process details of the theory, practice of operations, and recommendation for use of the technologies discussed above, as well as possibilities of further applications, are described in this paper. After learning the fundamentals of these processes, students are prepared to design and analyze parts as well as the process required for different machining capabilities. Methods to introduce students to the concepts of using laser and electron beams AM machine as well the prototype machining are described in the paper. Conclusions recommending the teaching methods of product SM and AM machining concepts and lessons learned are also pointed out.

Hub in the car faces high vibrations and centrifugal stresses. This calls for proper design and analysis. The life cycle of any formula car should be less which is adequate for racing purpose. This work is focused in analyzing low cycle fatigue and conducting vibratory analysis of a split hub of FSAE car. Stress concentration factor is significant in machine elements which give rise to localized stresses for any change in design of surface or abrupt change in cross section. This member acts as stress riser which leads to localized stresses in turn leading to peak stresses introducing cracks. These cracks may propagate and leads to catastrophic failure of machine elements and these conditions leads to fatigue analysis to calculate life. Two approaches are employed here. Based on linear elastic finite element analysis Neuber stresses are calculated from fictive elastic results. Strain Amplitude approach is followed by Coffin-Manson equation to determine Fatigue life. The failure induced by fretting fatigue due to two contact surfaces subjected to an oscillatory loading serves as premature crack nucleation which will gradually become a prominent issue during the running of car. In some cases it reduces the life due to micro slip at the edge of contact. The split pieces of hub talk to each other and create wear which is calculated by fretting. These rotary parts call for structurally rigid geometry. Modes with relatively high mode participation factor can be readily excited by the base vibrations. Vibratory stresses arise due to engine and rotating wheels acts like excitation frequencies which may lead to possible resonance. Campbell diagram is effectively used to modify the stiffness in turn design. Also an approach is done for design optimization of fillet stresses at Sharp edges caused due to bending strength of the split pieces. Optimization of diameter, contact region, root land dimensions is done to ensure stress distribution is uniformly spread along the fillet radius on both pieces of hub which otherwise may lead to crack initiation considering all peak stresses. Design of Experiments technique and optimization methods are used to improve structural integrity by finding the peak sectional stress. Design optimization is done using screening method to ensure strength of material.

Processing of metals in industries is lifeline of economy of country, which helps to shape the country. Energy saving in this process is attributed to both the parts ie process of machining and energy consumed in machine tools itself. The process of material removal had experienced lot of improvements in last few decades. This consists of developments in pre-machining processes, metal cutting methods and developments in cutting theories and cutting tools. Cutting fluid is one of challenging field to yield more favourable results. Manufacturing practices beyond its existing limits, process and machine automations, using the previous data for improving machinabilities, optimizing through relative benchmarks (a market driven schemes) shall lead the manufacturing speed to a new high. Adaptibility of manufacturing set up to absorb new requirement will also be a controlling factor for acceleration of manufacturing processes. This paper discusses the efforts to reduce the energy to produce a product. Various methods are discussed to minimize the energy consumed for driving the machine components such as spindle, feeding device, lubricating system, cutting fluid system, indexing and tooling management, speed and feed controlling devices etc. Different requirements such as friction energy in braking action, speed reducing or cushioning will also consume certain amount of energy during its operations. Therefore one has to understand the various types of energy flows and classification of energy forms used from place to place. Study of constructional features of machines brings a lot of opportunities for savings in energy. The concepts of material handling, fluid handling like hydraulic and pneumatic circuits, lubrication system, shall also provide the opportunities for savings in energy consumption. Energy used for working of accessories whether they are required at that particular moments needs to be considered from time to time. There are few more methods for locating the chances for arresting the energy wastages and reducing specific energy consumption referring a particular process or function. Previous data generated for similar functions can be referred for comparison and efforts can be added to reduce the requirement of energy. Efficient and effective utilization of equipment shall open a fresh path for finding the energy reductions. Sustainability of machining processes can be ensured for future using the lean energy utilizations for productions. Authors have explained the live cases to demonstrate reduction in energy consumption. Few potential guidelines are also narrated in this line. Further few cases are discussed from literature survey which support and will help to pursue the target.