Development of energy consumption map for orthogonal machining of Al 6061-T6 alloy

Salman Sagheer Warsi, Syed Husain Imran Jaffery*, Riaz Ahmad, Mushtaq Khan, Liaqat Ali, Mujtaba Hassan Agha, Sohail Akram

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

42 Citations (Scopus)

Abstract

The major source of environment and economic impact of machine tools has been attributed to their energy consumption. This article, therefore, proposes a novel energy mapping approach to evaluate specific cutting energy consumption with respect to cutting parameters. Unlike the studies presented earlier, which are machine-tool-specific, this study focuses on the basic tool–workpiece interaction for energy consumption analysis. The presented energy map reveals different energy consumption regions at varying machining parameters (feed and speed) during orthogonal machining of Al 6061-T6 alloy. The chip formation analysis indicates a strong correlation with the different energy consumption regions identified on the energy map. It has been observed that feed is the major contributing factor towards shear plane angle during chip formation as compared to cutting speed. Therefore, increasing feed results in a higher shear angle and consequently lowering the specific cutting energy as indicated on the energy map. Selection of machining parameters corresponding to the lowest specific cutting energy consumption region, as identified on the energy map, can result in energy savings up to 27% per kg of material removed. The developed map can be used for selection of suitable energy-efficient cutting parameters.

Original languageEnglish
Pages (from-to)2510-2522
Number of pages13
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume232
Issue number14
DOIs
Publication statusPublished - 19 Apr 2017
Externally publishedYes

Keywords

  • Aluminium alloy
  • green manufacturing
  • orthogonal machining
  • specific cutting energy consumption
  • sustainable manufacturing
  • turning

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