Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA

Machine tools are responsible for environmental impacts owing to their energy consumption. Cutting parameters have been optimized to minimize cutting power, power consumed or cutting energy. However, these response variables do not consider the energy demand that ensures the readiness of the machine tool. The present paper outlines an experimental study to optimize cutting parameters during turning of AISI 6061 T6 under roughing conditions in order to get the minimum energy consumption. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) were employed to analyze the effects and contributions of depth of cut, feed rate and cutting speed on the response variable. A comparison was done to highlight the importance of correctly selecting the response variable to be analyzed, due to the difference of the values of cutting parameters needed to optimize cutting power, cutting energy, power consumed and energy consumed during the machining process. Additional, the relationship between cutting parameters, energy consumption, and surface roughness was analyzed in order to determine the levels of the cutting parameters that lead to minimum energy consumption and minimum surface roughness. The results of this research work showed that feed rate is the most significant factor for minimizing energy consumption and surface roughness. Nevertheless, the level of this factor needed to achieve minimum energy consumption is not the same as the one needed to obtain minimum surface roughness. Higher feed rate provides minimum energy consumption but will lead to higher surface roughness. •Energy consumed during machining is the variable that must be optimized.•For minimizing energy consumed, feed rate is the most significant factor (87.79%).•For minimizing surface roughness, feed rate is the most significant factor (98.06%).•Higher feed rate minimizes the energy consumption but maximizes surface roughness.