Modelling of energy and related parameters during milling: Review and discussions

Abstract

Manufacturing is one of the key activities used to assess any industrialized countries economic strength. Machining is a well-liked manufacturing process and milling is a widespread metal removing process for the production of complex profile components. High energy consumption during the machining process results in higher energy usage, more toxic pollution and higher energy prices. Hence for cost reduction and to ensure economic in addition to environmental sustainability, reducing power usage is a significant factor. Along with the amount of consumption in energy reduced, the improvement in energy efficiency and power factor are also important factors to improve sustainability in this segment. The energy consumption, energy efficiency and power factor during machining are dependent on different process parameters like feed rate, geometry of the cutter, cutting speed, material of the cutter, depth of cut, material of the workpiece and cutting environment. So, that choice of the optimum values of these process parameters is one of the key approaches to improve the machining performance. The literature on energy modelling and associated parameters using theoretical, empirical and experimental techniques for milling operations is discussed in this article. It illustrates the approach used for the model and the significance of these works. Theoretical and empirical models are initially examined, accompanied by discussions on experimental models developed using design of experiments. The paper seeks to point out the recent developments in the modelling of energy and related parameters for milling operations and also to discover the regions that needs to be considered for future studies.