Selection of optimum cutting parameters for minimization of specific energy consumption during machining of Al 6061

Abstract

Manufacturing sector consumes a significant amount of energy globally. Machine tools are one of the major equipment in manufacturing sector and hence major consumer of energy. The electrical energy consumed by the machine tools results in emission of harmful gases and substantial stress on environmental. This work focuses on selection of optimum cutting parameters to minimize specific energy consumption (SEC) during turning of Al 6061 with tungsten carbide inserts in dry condition. Experiment are planned using L27 orthogonal array and Taguchi method is applied to determine optimum and most influencing cutting parameters for minimizing SEC. Results shows that feed is the dominating factor followed by cutting speed and depth of cut. The optimum value of feed (mm/rev), cutting speed (m/min) and depth of cut (mm) are found 0.12, 46.2 and 1.0 respectively. Further the energy consumption maps are developed to analyse the influence of cutting parameters on specific energy consumption. The developed energy consumption maps can be used for correlating the region of minimum SEC with selected cutting parameters.