Sustainability-Based Analysis of Conventional to High-Speed Machining of Al 6061-T6 Alloy

Abstract

High-speed machining is considered to be a promising machining technique due to its advantages, such as high productivity and better product quality. With a paradigm shift towards sustainable machining practices, the energy consumption analysis of high-speed machining is also gaining ever-increasing importance. The current article addresses this issue and presents a detailed analysis of specific cutting energy (SCE) consumption and product surface finish (Ra) during conventional to high-speed machining of Al 6061-T6. A Taguchi-based L16 orthogonal array experimental design was developed for the conventional to high-speed machining range of an Al 6061-T6 alloy. The analysis of the results revealed that SCE consumption and Ra improve when the cutting speed is increased from conventional to high-speed machining. In particular, SCE was observed to reduce linearly in conventional and transitional speed machining, whereas it followed a parabolic trend in high-speed machining. This parabolic trend indicates the existence of an optimal cutting speed that may lead to minimum SCE consumption. Chip morphology was performed to further investigate the parabolic trend of SCE in high-speed machining. Chip morphology revealed that the serration of chips initiates when the cutting speed is increased beyond 1750 m/min at a feed rate of 0.4 mm/rev.

Computer-aided design system for the end mill made by laser ablation and grinding

“…Movement 𝑥𝑦 the cutter tooth is formed by a rotational movement at an angle 𝜃 and an associated translational movement at a distance the cutting tooth is described by equation (1,2).…”

“…High-speed multi-axis machining is one of the most high-tech areas of engineering. High machining tools require high thermal loads, rotating stress levels, severe heat dissipation conditions, and high chip shapes [1][2][3][4][5][6].…”