Cutting Path-associated Energy Consumption of Milling Machining Process

Abstract

Manufacturing industries face numerous challenges, such as reducing their energy consumption. Minimising energy usage is one of the initiatives towards sustainable manufacturing. Many researches have studied the surface quality of machined part, but studies on energy consumption during machining process are limited. Different cutting paths operations may influence energy consumption during machining. The objective of this research was to investigate the effect of cutting tool paths and parameters on energy consumption during machining. Aluminium 6061 alloy was face-milled using high-speed steel tool with different tool paths, namely, morphed spiral, parallel and spiral paths. The design of experiment technique was applied to optimise the experimental work, and response surface methodology was used to analyse the experimental result. Results showed that feed rate is the most influential parameter on the energy consumption of machining. Machining energy models were also generated for morphed spiral, parallel and spiral cutting paths. The R 2 of each model was higher than 0.92, which indicates that the model equations are applicable in predicting the energy consumption of a milling operation.

Optimization Experimental Study of Machining Energy Consumption of Zig-Zag Milling Cutting Path Using Rsm.

“…Meanwhile, Ke Xu and Kai Tang [22] investigated the influence of feed rate, axial and radial depth of cut on energy consumption during rough milling operation. AR Hemdi et al [23] [24] studied the machining energy of various tool paths, including parallel, morphing spiral, and spiral, and discovered that the feed rate and spindle speed were the significant parameters influencing the energy of machining for all three cutting paths studied. High feed rate increases the material removal rate and reduces the cutting time, which may lower the energy usage.…”