Energy crisis, climate change, and stringent legislations are imposing great pressure on enterprises, especially manufacturing sectors, to improve their energy efficiency. To achieve higher energy efficiency in manufacturing, reliable energy consumption modelling is the prerequisite since it offers fundamental basis for any energy efficiency-related optimization. Although tool wear is inevitable, traditional energy consumption models fail to take tool wear effects into consideration. To address this issue, this study proposes an energy consumption model with tool wear progression for 3-axis milling process. Based on modern machining theory and recent achievements in energy consumption modelling, the proposed model is firstly derived as an expression with unknown coefficients. Subsequently, the involved coefficients are calibrated based on cutting experiments. With the explicit energy consumption model, power consumption with a given tool wear under new cutting conditions can be predicted with a high accuracy. In addition, as the model reveals a one-to-one correspondence between the power consumption and tool wear, the tool wear can also be effectively estimated from the measured power consumption. Compared with other tool wear monitoring methods such as acoustic emission and vibration, this power consumption-based tool wear estimation method is not only straightforward but also cost-effective. To the best of the authors' knowledge, the proposed energy consumption model with tool wear progression is the first model that was experimentally validated in terms of total power prediction and tool wear prediction, respectively. As such, the proposed model can be a significant supplement to existing energy consumption modelling in machining process, and may provide a more accurate and comprehensive platform for energy efficiency optimization.

能源危机，气候变化和严格的法规正向企业，特别是制造业部门施加巨大的压力，以提高其能源效率。为了在制造中实现更高的能源效率，可靠的能源消耗建模是前提条件，因为它为任何与能源效率相关的优化提供了基础。尽管刀具磨损是不可避免的，但传统的能耗模型无法考虑刀具磨损的影响。为了解决这个问题，本研究提出了一种用于三轴铣削过程的具有刀具磨损进度的能耗模型。基于现代加工理论和能耗建模的最新成果，首先将所提出的模型作为系数未知的表达式推导。随后，根据切削实验对涉及的系数进行校准。利用显式的能耗模型，可以高精度地预测在新的切削条件下具有给定刀具磨损的能耗。此外，由于该模型揭示了功耗与工具磨损之间的一一对应关系，因此也可以从测量的功耗中有效地估算出工具磨损。与其他工具磨损监测方法（例如声发射和振动）相比，这种基于功耗的工具磨损估计方法不仅简单明了，而且具有成本效益。据作者所知，所提出的具有工具磨损进度的能耗模型是第一个在总功率预测和工具磨损预测方面分别通过实验验证的模型。