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

Abstract

Machining operations in CNC milling which remove the work material require power and energy to activate the machine components such as spindle motor, table and tool movement in order to withstand the high friction and load between tool and work material. Energy consumption during cutting operation is greatly influenced by the machining condition and parameters. This experimental research aims to investigate how energy responds to changes in the machining parameters such as depth of cut, spindle speed, and feed rate during face milling operation of CNC machine. The high-speed steel (HSS) tool with a 10mm diameter was used to face mill the 40mm x 40mm of Aluminum 6061. The design of experiment technique using Response Surface Methodology (RSM) is utilized to optimize the experimental work. Power usage and machining time were recorded for each machining process, which is then used to determine the machining energy consumption. The interaction between machining parameter and energy is comprehensively visualized using surface and contour plot. Additionally, the ANOVA analysis investigates the feed rate as the most influential parameter to the machining energy. Finally, the regression equation of machining energy is generated with reliability (R) value of 0.88 which can be used as an energy prediction model.