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

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. © 2018, Springer-Verlag London Ltd., part of Springer Nature.