Sustainability-Based Analysis of Conventional to High-Speed Machining of Al 6061-T6 Alloy
Source abstract
Abstract
High-speed machining is considered to be a promising machining technique due to its advantages, such as high productivity and better product quality. With a paradigm shift towards sustainable machining practices, the energy consumption analysis of high-speed machining is also gaining ever-increasing importance. The current article addresses this issue and presents a detailed analysis of specific cutting energy (SCE) consumption and product surface finish (Ra) during conventional to high-speed machining of Al 6061-T6. A Taguchi-based L16 orthogonal array experimental design was developed for the conventional to high-speed machining range of an Al 6061-T6 alloy. The analysis of the results revealed that SCE consumption and Ra improve when the cutting speed is increased from conventional to high-speed machining. In particular, SCE was observed to reduce linearly in conventional and transitional speed machining, whereas it followed a parabolic trend in high-speed machining. This parabolic trend indicates the existence of an optimal cutting speed that may lead to minimum SCE consumption. Chip morphology was performed to further investigate the parabolic trend of SCE in high-speed machining. Chip morphology revealed that the serration of chips initiates when the cutting speed is increased beyond 1750 m/min at a feed rate of 0.4 mm/rev.
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Research context
OpenAlex topics: Advanced Machining and Optimization Techniques · Advanced machining processes and optimization · Energy Efficiency and Management
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Mechanical Engineering, Capital University of Science and Technology, Islamabad 44000, Pakistan
Nust Business School, National University of Science & Technology, Islamabad 44000, Pakistan
Department of Mechanical and Aerospace Engineering, Sapienza University of Rome, 00185 Rome, Italy
Department of Materials Science and Engineering, Pak-Austria Fachhochschule Institute of Applied Sciences and Technology, Haripur 22620, Pakistan
Department of Mechanical Engineering and Technology, Government College University, Faisalabad 38000, Pakistan
Department of Mechanical Engineering, Institute of Space Technology, Islamabad 44000, Pakistan
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