Energy Analysis during Milling Machining of Aluminum Alloy 6061

Abstract

The conservation of energy is a matter of global concern and optimum utilization of energy is necessary for a prosperous future. Industrial sector being the biggest power consumption sector with manufacturing industry being the sector leader calls for the need of effective means to reduce the consumption of power through process and product optimization. The optimization of energy consumption will not only contribute towards the conservation of energy but will also result in reduced production costs and improved environment for sustainment of safe and flourishing life. The excessive consumption of oil in last few decades has triggered the need for energy efficient processes across globe and manufacturing industry being the major consumer becomes the major concern. This thesis focuses on the evaluation of various parameters in milling machining for their impact on specific cutting energy consumption during the process and measure for their optimization. The purpose of this thesis is to evaluate the variation in specific cutting energy with variation in speed, feed, depth of cut and width of cut. The parameters selected for consideration have been based upon their high impact on power consumption in a machining process. The impact factor or significance of each of the factor has been reviewed during the thesis for better optimization of machining process and selection of correct parametrial values for energy efficient machining. The thesis establishes the feed as the most significant factor for energy consumption followed by speed, depth of cut and width of cut. The results obtained are then compared with the results available in literature for turning operations and significant factors of the comparison are discussed in detail. The thesis has further proved the conclusion that machining parameters selection if carefully made can have a significant impact on power consumption during a machining process. It also discusses the limitations of milling operations on power consumption in comparison to the turning operations.