Determination of Energy Consumption during Turning of Hardened Stainless Steel Using Resultant Cutting Force

Abstract

Downsizing energy consumption during the machining of metals is vital for sustainable manufacturing. As a prerequisite, energy consumption should be determined, through direct or indirect measurement. The manufacturing process of interest is the finish turning which has been explored to generate (near) net shapes, particularly for hardened steels. In this paper, we propose using measured cutting forces to calculate the electrical energy consumption during the finish turning process of metals where typically the depth of cut is lower than the cutting tool nose radius. In this approach, the resultant cutting force should be used for calculating the energy consumption, instead of only the main (tangential) cutting force as used in the conventional approach. A case study was carried out where a hardened stainless steel (AISI 420, hardness of 47–48 HRC) was turned using a coated carbide tool, with a nose radius of 0.8 mm, without cutting fluid, and at 0.4 mm depth of cut. The experimental design varied the cutting speed (100, 130, and 170 m/min) and feed (0.10, 0.125, and 0.16 mm) while other parameters were kept constant. The results indicate that the electrical energy consumption during the particular dry turning of hardened steel can be calculated using cutting force data as proposed. This generally means machining studies that measure cutting forces can also present energy consumption during the finish or hard turning of metals, without specifically measuring the power consumption of the machining process. For this particular dry turning of hardened stainless steel, cutting parameters optimization in terms of machining responses (i.e., low surface roughness, long tool life, low cutting force, and low energy consumption) was also determined to provide an insight on how energy consumption can be integrated with other machining responses towards sustainable machining process of metals.

Cutting Energy Consumption Modelling of End Milling Cutter Coated with AlTiCrN

“…The cutting width b is regarded as a e , and the workpiece thickness h is regarded as a p . Therefore, the cutting power with the sharp cutting edge can be calculated by Equation (11).…”

“…Before applying this model, the finite element method can be adopted to simulate the metal properties [26,27]. The cutting width b is regarded as ae, and the workpiece thickness h is r Therefore, the cutting power with the sharp cutting edge can be calculated (11). ( )…”

“…According to Equation (11), plastic deformation energy is related to cutting width, cutting depth and feed rate. The friction energy on rake face is related to spindle speed, cutting width and cutting depth, and the flank face friction energy is related to spindle speed and cutting width.…”

“…the degree of tool wear has a significant effect on the net specific cu researchers study the influence of various parameters on energy ferent perspectives and provide new ideas for the study of energy Liu et al [9] and Zhang et al [10] consider the size effect of sp per tooth, axial cutting depth, and radial cutting width in the pow propose the using of measured cutting forces to calculate the elec Liu et al [9] and Zhang et al [10] consider the size effect of specific cutting force, feed per tooth, axial cutting depth, and radial cutting width in the power model. Nur et al [11] propose the using of measured cutting forces to calculate the electrical energy consumption during the finish turning process of metals. Refs.…”

Tribo-Device to Quantify of Friction in Rake Face Using Line Contact Mechanism Under Different Machining Conditions. (c2021)

“…In metal cutting processes, the rake face of cutting tools suffer from high contact pressure and temperature due to aggressive shearing and sliding actions, thus impacting the tool life and surface quality. In addition, 20% of the total energy generated during metal cutting is consumed to overcome the friction forces occurred between the tool and the workpiece [23]. Therefore, controlling the frictional contact can reduce the production cost and increase the production rate [24].…”