An environment-friendly sustainable machining solution to reduce tool consumption and machining time in face milling using a novel wiper insert

Abstract

Machining is a high energy-consuming manufacturing process that also generates an enormous amount of waste in the form of chips and worn tools. With governments focusing on reducing the environmental footprint by switching to renewable energy sources and enforcing stricter regulations, industries have started looking for sustainable practices in machining as well. However, a detailed strategy with a multipronged approach in the product design, process, and system is required to transform machining into an eco-friendly process. In addition, developing a sustainable machining solution must be attempted without compromising the other critical performance characteristics of the tools. Hence, the article reports the development (design and manufacturing) of a new wiper milling insert and the investigations carried out to evaluate the sustainability quotient of the tool such as machining power, specific cutting energy, total machining time, and tool consumption. The study confirms that the new wiper milling insert can assist in combining the rough and finish machining steps into one without increasing the power consumption, which reduces the number of tools required for machining. In addition, a 50% reduction in machining time and a significant improvement in surface finish can be obtained simultaneously using the wiper insert.