This paper presents an integrated process-machine approach based on stability lobe diagrams for designing large-volume milling machines bearing in mind their productivity, reliability and accuracy as well as their eco-efficiency. In fact, eco-efficiency of machining processes is an issue of increasing concern among both machine tool builders and manufacturers. Thus, this work introduces a global modelling of the dynamics of milling machines and of milling processes with a goal of supporting engineers in the design of machine tools that result in optimal machining productivity at minimised environmental impacts and costs. This is a result of reducing the machines' material content, and consequently resulting in lowered energy consumption. This approach has been implemented in the design of an actual milling machine, upon which machining tests have been conducted that have shown an increase of 100% in productivity while consuming 1.5% less energy due to a weight reduction of over 20% in structural components. Thus highly productive machining processes and eco-efficient milling machines have been integrated in one unique system.
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