TY - JOUR
T1 - Development of energy consumption map for orthogonal machining of Al 6061-T6 alloy
AU - Warsi, Salman Sagheer
AU - Jaffery, Syed Husain Imran
AU - Ahmad, Riaz
AU - Khan, Mushtaq
AU - Ali, Liaqat
AU - Agha, Mujtaba Hassan
AU - Akram, Sohail
N1 - Publisher Copyright:
© IMechE 2017.
PY - 2017/4/19
Y1 - 2017/4/19
N2 - 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.
AB - 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.
KW - Aluminium alloy
KW - green manufacturing
KW - orthogonal machining
KW - specific cutting energy consumption
KW - sustainable manufacturing
KW - turning
UR - http://www.scopus.com/inward/record.url?scp=85044691993&partnerID=8YFLogxK
U2 - 10.1177/0954405417703424
DO - 10.1177/0954405417703424
M3 - Article
AN - SCOPUS:85044691993
SN - 0954-4054
VL - 232
SP - 2510
EP - 2522
JO - Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
JF - Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
IS - 14
ER -