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Numerically Constructed Energy Consumption Mapping for the Orthogonal Machining of Ti6Al4V


 Energy efficiency is an important aspect of all industrial processes. Sustainability in manufacturing sector can be improved by reducing and optimizing the energy requirements of the machine tool during the machining process. Growing energy demand and shortages in conventional energy sources have prompted research into energy conservation and sustainable development. Machining of difficult-to-cut materials such as titanium-based alloys involve high consumption of energy and hence it is compulsory to study the optimal combinations of process parameters that yield the best result with highest efficiency in terms of energy. This paper aims to develop a finite element (FE) assisted virtual energy consumption map for the machining of Ti6Al4V in orthogonal turning operation. The cutting power for the machining process is simulated in AdvantEdge specially designed machining software for specific cutting parameters. The map developed is universally applicable and independent of the machine tool as only cutting power is used. The visual energy map can be utilized at the shop floor level, as it is easily understandable to the operator. The information enabled through the map can help the operator select the optimal combination of process parameters for the machining process and maximize the energy based efficiency of the cutting process.