Development of specific cutting energy map for sustainable turning: a study of Al 6061 T6 from conventional to high cutting speeds

This study presents the development of a novel Specific Cutting Energy (SCE) based process map for turning of Al 6061 T6 alloy from conventional to high-speed machining range. The newly developed SCE map for turning process was compared with already published SCE maps for orthogonal machining. The comparison of maps revealed that SCE consumption trends observed in turning process are similar to those observed in orthogonal machining. Low values of SCE were observed at high cutting speeds and high feed rates that demonstrate the benefit of high-speed machining. Similar to the orthogonal machining SCE map, a high energy consumption zone named as “avoidance zone” was observed at high cutting speeds and low feed rates. Surface roughness analysis performed in the avoidance zone established the presence of built-up-edge on cutting inserts that not only resulted in high energy consumption but also deteriorated the surface finish of the machined part. Furthermore, statistical analysis of experimental data also revealed the significant effect of tool nose radius on SCE consumption in high-speed machining range. This significance of tool nose radius for SCE consumption has not been reported earlier in literature.