Optimum Swept Angle Estimation based on the Specific Cutting Energy in Milling AISI 1045 Steel Alloy

Authors

1 College of Engineering, Department of Mechanical & Mechatronics Engineering, Afe Babalola University, Ado Ekiti, Nigeria

2 Faculty of Engineering, Department of Mechanical Engineering, Akwa Ibom State University, Ikot Akpaden, Uyo, Akwa Ibom State, Nigeria

Abstract

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining processes with various parameters determined. The aim of this work is to investigate the impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This is achieved by varying the step over at different feed rate values in order to determine the optimization criterion for machining. It was observed that an optimum swept angle of 31.8o was appropriate in the elimination of ploughing effect and reducing the specific cutting energy to an optimised minimum value. However, higher swept angle of 41.4o increases the specific cutting energy with a higher machine tool power. This is attributable to the reduction in the cycle time caused by shorter toolpath length. The results obtained further elucidate the knowledge base for the determinations of optimum parameters for sustainable machining and resource efficiency of manufactured products.

Keywords


1.     Caruana, A., Said, E., Williams, L. and Krentler, K., "Corporate reputation, service quality and attitude toward price: The case of an energy utility", in Proceedings of the Academy of Marketing Science (AMS) Annual Conference, Springer., (2015), 420-425.
2.     Balogun, V.A., Edem, I.F. and Mativenga, P.T., "The effect of auxiliary units on the power consumption of cnc machine tools at zero load cutting", International Journal of Scientific & Engineering Research,  Vol. 6, No. 2, (2015), 874-879.
3.     Balogun V.A, "Power analysis for machine tool states: Critical factors towards a more robust machine tool energy model", in 7th Proceedings of the International Science, Technology, Engineering, Arts, Management and Social Sciences (iSTEAMS), University of Ilorin, Nigeria., (2015), 613 - 620.
4.     Chen, C.-C., "Incorporating green purchasing into the frame of iso 14000", Journal of Cleaner Production,  Vol. 13, No. 9, (2005), 927-933.
5.     Dahmus, J.B. and Gutowski, T.G., "An environmental analysis of machining", in ASME international mechanical engineering congress and exposition, American Society of Mechanical Engineers., (2004), 643-652.
6.     Gutowski, T., Dahmus, J. and Thiriez, A., "Electrical energy requirements for manufacturing processes", CIRP international conference on life cycle engineering., (2006), 623-638.
7.     Balogun, V.A., Aramcharoen, A., Mativenga, P.T. and Chuan, S.K., "Impact of machine tools on the direct energy and associated carbon emissions for a standardized nc toolpath, in Re-engineering manufacturing for sustainability", (2013), 197-202.
8.     Balogun, V.A. and Mativenga, P.T., "Modelling of direct energy requirements in mechanical machining processes", Journal of Cleaner Production,  Vol. 41, (2013), 179-186.
9.     Bhushan, R.K., "Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of al alloy sic particle composites", Journal of Cleaner Production,  Vol. 39, (2013), 242-254.
10.   Ghani, A. and Choudhury, I., "Study of tool life, surface roughness and vibration in machining nodular cast iron with ceramic tool", Journal of Materials Processing Technology,  Vol. 127, No. 1, (2002), 17-22.
11.   Mativenga, P. and Rajemi, M., "Calculation of optimum cutting parameters based on minimum energy footprint", CIRP Annals-Manufacturing Technology,  Vol. 60, No. 1, (2011), 149-152.
12.   Rajemi, M., Mativenga, P. and Aramcharoen, A., "Sustainable machining: Selection of optimum turning conditions based on minimum energy considerations", Journal of Cleaner Production,  Vol. 18, No. 10, (2010), 1059-1065.
13.   Boothroyd, G., "Fundamentals of metal machining and machine tools, Crc Press,  Vol. 28,  (1988).
14.   Balogun, V.A., Edem, I.F., Adekunle, A.A. and Mativenga, P.T., "Specific energy based evaluation of machining efficiency", Journal of Cleaner Production,  Vol. 116, (2016), 187-197.
15.   Balogun, V.A. and Mativenga, P.T., "Impact of un-deformed chip thickness on specific energy in mechanical machining processes", Journal of Cleaner Production,  Vol. 69, (2014), 260-268.
16.   Ducobu, F., Filippi, E. and Rivière-Lorphèvre, E., "Chip formation and minimum chip thickness in micro-milling", Proceedings of CIRP MMO,  (2009), 339-346.
17.   Korkut, I., Kasap, M., Ciftci, I. and Seker, U., "Determination of optimum cutting parameters during machining of aisi 304 austenitic stainless steel", Materials & Design,  Vol. 25, No. 4, (2004), 303-305.
18.   Tsai, M., Takata, S., Inui, M., Kimura, F. and Sata, T., "Operation planning based on cutting process models", CIRP Annals-Manufacturing Technology,  Vol. 40, No. 1, (1991), 95-98.
19.   Tarng, Y. and Shyur, Y., "Identification of radial depth of cut in numerical control pocketing routines", International Journal of Machine Tools and Manufacture,  Vol. 33, No. 1, (1993), 1-11.
20.   Hinduja, S., Ma, Y. and Barrow, G., "Determination of the radial width of cut and cutting modes in milling", International Journal of Machine Tools and Manufacture,  Vol. 35, No. 5, (1995), 689-699.
21.   Stephenson, D.A. and Agapiou, J.S., "Metal cutting theory and practice, CRC press,  (2016).
22.   Kalpakjian, S., "Manufacturing engineering and technology, Pearson Education India,  (2001).