Optimum Swept Angle Estimation based on the Specific Cutting Energy in Milling AISI 1045 Steel Alloy

Abstract

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining processes with various parameters determined. The aim of this work is to investigate the impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This is achieved by varying the step over at different feed rate values in order to determine the optimization criterion for machining. It was observed that an optimum swept angle of 31.8o was appropriate in the elimination of ploughing effect and reducing the specific cutting energy to an optimised minimum value. However, higher swept angle of 41.4o increases the specific cutting energy with a higher machine tool power. This is attributable to the reduction in the cycle time caused by shorter toolpath length. The results obtained further elucidate the knowledge base for the determinations of optimum parameters for sustainable machining and resource efficiency of manufactured products.