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Development and analysis of energy consumption map for high-speed machining of Al 6061-T6 alloy

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Abstract

Specific cutting energy consumption in high-speed orthogonal machining of Al 6061-T6 alloy has been analyzed in this work. The evaluated values of specific cutting energy are presented as an energy map developed over a cutting speed-undeformed chip thickness grid. Different regions characterized by energy consumption have been defined on the developed map. Very low values of specific cutting energy (up to 0.32 J/mm3) were observed for Al 6061-T6 alloy while machining over the cutting speed of 1500 m/min. Such low energy values have not been reported earlier in literature and they demonstrate another benefit of high-speed machining along with better surface finish, low cutting forces, and high production rate. The developed energy map revealed the presence of a very high energy zone in the midst of a comparatively low energy consumption region. A detailed analysis was performed to investigate the formation of this high energy zone or “avoidance zone.” The analysis of results revealed excessive built-up edge formation within this zone.

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Correspondence to Salman Sagheer Warsi.

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Warsi, S.S., Jaffery, S.H.I., Ahmad, R. et al. Development and analysis of energy consumption map for high-speed machining of Al 6061-T6 alloy. Int J Adv Manuf Technol 96, 91–102 (2018). https://doi.org/10.1007/s00170-018-1588-7

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Keywords

  • Built-up edge
  • Energy map
  • High-speed machining
  • Specific cutting energy