Abstract
Energy consumption in precision cutting has a significant impact on manufacturing cost and environmental impact. However, the characteristics of energy consumption in hard milling at the machine, spindle, and the process level remain unclear. In particular net cutting specific energy consumed in surface generation is yet to understand. This study explores power and energy consumption characteristics in hard milling by examining the relationships between power, energy consumption, and process parameters including tool wear. A new set of parameters has been defined to characterize power and energy characteristics. Tool wear has the greatest influence on net cutting specific energy compared with feed and cutting speed. Traditional empirical models may predict specific energy at machine and spindle levels, but lack accuracy when describing net cutting specific energy. A power regression model was developed to predict net cutting specific energy with high accuracy. Material removal rate (MRR) was found not to be a unique identifier for net cutting specific energy. Energy efficiency increased with MRR. In addition, up milling consumed slight more energy than down milling.
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