Experimental and Numerical Assessment of Sustainable Machine Tool Design: A Life Cycle Perspective on Structural Optimization and Energy Performance

Year : 2026 | Volume : 17 | Issue : 02 | Page : 13 39
By

Nagendra Singh,

Sanjeev Kumar Verma,

Diksha Jain,

Gopal Sharma,

Devendra Singh Chauhan,

  1. Assistant Professor, Department of Mechanical Engineering, Institute of Engineering and Technology, Dr. Bhimrao Ambedkar University, Swami Vivekanand Campus, Khandari, Agra, Uttar Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Central Instrumentation Facility Research and Development Cell, Lovely Professional University, Phagwara, Punjab, India
  3. Assistant Professor, Department of Civil Engineering, Institute of Engineering and Technology, Dr. Bhimrao Ambedkar University, Swami Vivekanand Campus, Khandari, Agra, Uttar Pradesh, India
  4. Associate Professor, Department of Mechanical Engineering, Eshan College of Engineering Near Raipura Jaat, Mathura, Uttar Pradesh, India
  5. Assistant Professor, Department of Mechanical Engineering, Axis Institute of Technology and Management, Kanpur, Uttar Pradesh, India

Abstract

Machine tools are high-mass, energy-intensive systems with long service lives, contributing significantly to the carbon footprint of manufacturing. Enhancing their sustainability requires integrated structural and energy optimization without compromising functionality, accuracy, or productivity. While sustainable design has been studied broadly, systematic reviews from an experimental and applied mechanics perspective remain limited. This paper reviews sustainable machine tool design through a life cycle lens, emphasizing mechanics-based strategies and assessment methods. Key technologies are categorized by life cycle stage and evaluated for their impact on structural integrity and energy consumption. Component-level structural optimization via topology optimization and bionic design for light weighting. Modular configurations and layout optimization to improve stiffness-to-mass ratio. Reduction of cutting fluids through minimum quantity lubrication, dry machining, and cryogenic techniques, and their effect on thermal-mechanical loads. Experimental modeling of energy use during cutting and idle states. Design for reuse, remanufacturing, and recycling to minimize material waste. Sustainability assessment methods such as experimental energy modeling, life cycle costing, and structural life prediction are discussed. This review provides designers with mechanics-driven strategies to enhance machine tool sustainability, linking structural design choices to life cycle energy and environmental performance. The study identifies critical gaps in experimental validation of sustainable design techniques and proposes directions for future applied mechanics research.

Keywords: Machine tools; Structural optimization; Life cycle assessment; Energy modeling; Sustainable design; Topology optimization; Experimental mechanics; Lightweight structures

[This article belongs to Journal of Experimental & Applied Mechanics ]

How to cite this article: Nagendra Singh, Sanjeev Kumar Verma, Diksha Jain, Gopal Sharma, Devendra Singh Chauhan. Experimental and Numerical Assessment of Sustainable Machine Tool Design: A Life Cycle Perspective on Structural Optimization and Energy Performance. Journal of Experimental & Applied Mechanics. 2026; 17(02):13-39.
How to cite this URL: Nagendra Singh, Sanjeev Kumar Verma, Diksha Jain, Gopal Sharma, Devendra Singh Chauhan. Experimental and Numerical Assessment of Sustainable Machine Tool Design: A Life Cycle Perspective on Structural Optimization and Energy Performance. Journal of Experimental & Applied Mechanics. 2026; 17(02):13-39. Available from: https://journals.stmjournals.com/joeam/article=2026/view=254019

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Regular Issue Subscription Review Article
Volume 17
Issue 02
Received 14/06/2026
Accepted 23/06/2026
Published 13/07/2026
Publication Time 29 Days

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