Plastic deformation-based energy consumption modelling for machining

To predict energy consumption in machining, a mathematical modelling method to mimic the cutting energy consumption during machining is proposed in this paper. The established model is based on the law of energy conservation. The mechanical material property coefficients and cutting parameters are included in the model by using material deformation theory and friction calculation which are used to represent the phenomena in machining. Cutting energy of material removal process is refined by analysing the effect of tool edge geometry. In addition, the machining process is divided into two machining elements, linear element and circular arc element, of which energy consumptions are established based on the principal theories above. Calculation method on the instantaneous cutting thickness for circular arc elements is proposed. Finally, a test example is given to validate the proposed modelling approach. With the proposed method, the separate impacts of the factors (e.g. cutting parameters, workpiece, tool) have been analysed and the physical background behind the known experimental dependence of the cutting parameters on cutting energy is revealed.