Sustainability analyses of cutting edge radius on specific cutting energy and surface finish in side milling processes

Abstract

The aim of this work is to determine the influence of cutting edge radius on the specific cutting energy and surface finish in a mechanical machining process. This was achieved by assessing the direct electrical energy demand during side milling of aluminium AW6082-T6 alloy and AISI 1018 steel in a dry cutting environment using three different cutting tool inserts. The specific energy coefficient was evaluated as an index of the sustainable milling process. The surface finish of the machined parts was also investigated after machining. It was observed that machining with the 48.50-μm cutting edge radius insert resulted in lower specific cutting energy requirements when compared with the 68.50 and 98.72-μm cutting edge radii inserts, respectively. However, as the ratio of the undeformed chip thickness to cutting edge radius is less than 1, the surface roughness increases. The surface roughness values gradually decrease as the ratio of undeformed chip thickness to cutting edge radius (h/r e) tends to be 1 and at minimum surface roughness values when the ratio of h/r e equalled to 1. However, the surface roughness values increased as h/r e becomes higher than 1. This machining strategy further elucidates the black box and trade-offs of ploughing and rubbing characteristics of micro machining and optimization strategy for minimum energy and sustainable manufacture.