Assessment methodology and cutting parameters-based decision-making for minimizing the environmental impact of machining

Machining remains a key manufacturing process for high-value components but generates environmental impacts due to electrical energy consumption, cutting tool wear and auxiliary consumables. Current research often focuses on energy efficiency, while the contribution of tool wear and process parameters to overall environmental impacts remains insufficiently quantified. This study proposes a comprehensive methodology combining Life Cycle Assessment, machining process modeling and sensitivity analysis of cutting parameters in order to support environmentally optimized decision-making. The approach integrates analytical models of electrical energy consumption, cutting force prediction and tool wear estimation. Environmental impacts are evaluated using the Environmental Footprint 3.0 method with the Ecoinvent database. Experimental investigations were carried out during milling operations to validate the proposed models and quantify the environmental contributions of electricity and tool consumption. A sensitivity analysis of cutting parameters was then conducted to identify the most influential factors affecting environmental performance. Results show that both electrical energy and tool wear significantly influence environmental impacts depending on machining conditions. The proposed methodology enables process planners to identify machining strategies that minimize environmental impacts while maintaining productivity. Although applied here to milling operations, the methodology is generic and transferable to other manufacturing processes, other Life Cycle Assessment tools and other experimental or sensor-based characterization approaches.