Energy modeling for variable material removal rate machining process: an end face turning case

Material-cutting energy modeling is the key technology of energy modeling of machining process, being the foundation of energy optimization. The material-cutting power changes dynamically during variable-material removal rate (MRR) machining process. Hence, the energy characteristic of variable-MRR machining process is more complicated than that of constant-MRR machining process. In this paper, a modeling method of material-cutting energy for variable-MRR machining process is proposed. The dynamic power characteristics are fully considered in this method, and the impacts of cutting parameters on material-cutting energy are also considered. Experimental studies were conducted to obtain the fitting coefficients of the proposed energy model. Finally, energy calculations of four actual end face turning processes were performed. The results show that the predictive accuracy of all tested end face turning cases is above 90 %. The proposed method provides an accurate energy model for process planning in metal cutting process, which helps manufacturers determinate the energy-optimal process plan.