Energy based process signature for surface integrity in hard milling

Abstract

Every cutting process has a unique process signature correlating to surface integrity that is critical to the functionality of precision components. One metric for process signature is energy consumption. This study explores process signature by examining the relationship between energy consumption and surface integrity in hard milling. Energy consumption in surface generation has been analyzed using new characteristic parameters. Traditional empirical models lack accuracy when describing net cutting specific energy. It was found that net cutting specific energy is an effective process signature for surface integrity and that a process window exists to optimize energy consumption and surface integrity.