The present study aimed to implement a sustainable machining method to improve energy efficiency in helical milling (HM) of AISI 1020. Therefore, ultrasonic vibration is integrated with conventional helical milling to reduce cutting forces. A model was developed for power consumption in terms of cutting forces in x, y and z directions, tangential and axial feed speeds. Series of plain and ultrasonic vibration helical milling (UVHM) experiments are conducted using 10 and 8 mm diameter mill cutters at different working conditions and experimental results for cutting forces are collected. Formation of chip and its geometry are investigated using the cutting trajectories of the bottom cutting edges of the cutter. Cutting forces and power consumption are estimated related to chip geometry in plain and UVHM processes and compared. In UVHM, the axial force is reduced by around 47% as the ultrasonic vibration is applied in the axial direction and the power consumption is reduced by 34%. The results showed that ultrasonic vibration has a significant effect on chip morphology, cutting force and power consumption, indicating that ultrasonic vibration assisted machining has a wide application in manufacturing. The process parameters are optimised as 2000 rpm of cutter rotational speed, 156 rpm of cutter orbital speed and 0.3 mm of axial depth of cut using 8 mm diameter cutter and the chip thickness, chip depth and power consumption are found to be 0.3969 mm, 0.2665 mm and 835.6 W respectively at optimal working condition.

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The main aim of this work is to analyse the significance of cutting parameters on surface roughness and spindle vibrations while machining the AA6063 alloy. The turning experiments were carried out on a CNC lathe with a constant spindle speed of 1000rpm using carbide tool inserts coated with Tic. The cutting speed, feed rate and depth of cut are chosen as process parameters whose values are varied in between 73.51m/min to 94.24m/min, 0.02 to 0.04 mm/rev and 0.25 to 0.45 mm respectively. For each experiment, the surface roughness parameters and the amplitude plots have been noted for analysis. The output data include surface roughness parameters (Ra,Rq,Rz) measured using Talysurf and vibration parameter as vibration amplitude (mm/sec) at the front end of the spindle in transverse direction using single channel spectrum analyzer (FFT).With the collected data Regression analysis is also performed for finding the optimum parameters. The results show that significant variation of surface irregularities and vibration amplitudes were observed with cutting speed and feed. The optimum cutting speed and feed from the regression analysis were 77.0697m/min and 0.0253mm/rev. for the minimum output parameters. No significant effect of depth of cut on output parameters is identified.