Towards energy efficient milling of variable curved geometries

Development of energy efficient machining is the present focus to industries for reduction of energy consumption and making the manufacturing system more sustainable. The continuous fluctuation in force profile during machining of variable curved components creates a barrier in stable machining and in cutting power con-sumption. The fluctuation in force profile happens due to alteration in chip load in the presence of workpiece curvature. The current research work intends to develop an energy efficient machining strategy for milling of variable curved components where more uniform cutting force and power profiles are accomplished due to constant chip load along the peripheral length of curved geometry. The proposed strategy is compared with conventional cutting in order to confirm the acceptability of the present algorithm. The proposed algorithm involves mechanics of milling, cutting forces and cutting power consumption. It is formulated based on constant chip load by regulating entry angle of milling cutter according to workpiece curvature along the peripheral length. Thus, the cutting power fluctuation occurred due to variation of workpiece curvature is reduced by regulating tool-workpiece engagement. The energy consumption during machining is reduced almost 22 % using the proposed approach. It results into developing an energy efficient machining strategy for milling of variable curved geometry. It also provides stable machining process and increased tool life by reducing tool wear due to reduction of force fluctuation during metal removal process.

Automated summary

The development of energy efficient machining is currently a priority for industries to reduce energy consumption and make manufacturing systems more sustainable. Fluctuations in force profiles during machining of variable curved components hinder stable machining and result in varying cutting power consumption. This research aims to develop an energy efficient machining strategy for milling variable curved components, achieving more uniform cutting force and power profiles by maintaining a constant chip load along the peripheral length of the curved geometry. The proposed strategy is compared with conventional cutting to validate its effectiveness. By regulating the entry angle of the milling cutter according to workpiece curvature, the proposed algorithm reduces cutting power fluctuations caused by variations in workpiece curvature, resulting in a 22% reduction in energy consumption during machining. This strategy not only enables energy efficient milling of variable curved geometries but also improves the stability of the machining process and prolongs tool life by reducing force fluctuations during metal removal.