Assessment of cutting energy consumption and energy efficiency in machining of 4140 steel

Machining operations such as turning, milling, and drilling are commonly employed machining processes in industry. With the push toward a future of sustainable manufacturing, machining processes need to be evaluated and optimized accordingly. This paper focuses on the energy aspects in metal cutting and attempts to provide an overall assessment of energy consumption and energy efficiency against the operating conditions. Specifically, the effects of tool geometry and cutting parameters in turning of ANSI 4140 steel are investigated through numerical experiments using finite element simulation. The variables considered include cutting speed, rake angle, nose radius, and edge radius. The effects of these parameters on cutting energy consumption and cutting efficiency are analyzed. The results show that the effects of these parameters on cutting energy and cutting efficiency are different. Strategies for minimizing cutting energy and maximizing cutting efficiency are suggested.