Expe imen al echnique o analyze he in luence o cu ing
condi ions on speci ic ene gy consump ion du ing ab asi e me al
cu ing wi h hin discs
Muhammad Rizwan Awan
1
•He na
´n A. Gonza
´lez Rojas
1
•Jose
´I. Pe a Bena ides
2
•
Saqib Hameed
1
Recei ed: 13 Janua y 2021 / Re ised: 23 Ma ch 2021 / Accep ed: 9 June 2021
The Au ho (s) 2021
Abs ac Speci ic ene gy consump ion is an impo an
indica o o a be e unde s anding o he machinabili y o
ma e ials. The p esen s udy aims o es ima e he speci ic
ene gy consump ion o ab asi e me al cu ing wi h ul a-
hin discs a compa a i ely low and medium eed a es.
Using an expe imen al echnique, he cu ing powe was
measu ed a ou p ede ined eed a es o S235JR, in e -
me allic Fe-Al(40%), and C45K wi h di e en he mal
ea men s. The a ia ion in he speci ic ene gy consump-
ion wi h he ma e ial emo al a e was analyzed h ough
an empi ical model, which enabled us o dis inguish h ee
phenomena o ene gy dissipa ion du ing ma e ial emo al.
The he mal ea men and mechanical p ope ies o
ma e ials ha e a signi ican impac on he ene gy con-
sump ion pa e n, i s co esponding componen s, and cu -
ing powe . Duc ile ma e ials consume mo e speci ic
cu ing ene gy han b i le ma e ials. The speci ic cu ing
ene gy is he minimum ene gy equi ed o emo e he
ma e ial, and plowing ene gy is ound o be he mos sig-
ni ican phenomenon o ene gy dissipa ion.
Keywo ds Speci ic cu ing ene gy Speci ic ene gy
consump ion Me al cu ing wi h ab asi e disc Ab asi e
cu o ope a ion Cu ing in e me allic alloy Fe-Al (40%)
1 In oduc ion
The indus ial sec o is cu en ly esponsible o 85% o he
wo ld’s ene gy, wi h manu ac u ing accoun ing o 40% o
he ene gy used in he indus y [1]. To minimize he
en i onmen al impac and educe he p oduc ion cos s, a
educ ion o he ene gy consump ion is among he g ea es
challenges o he manu ac u ing indus y [2,3]. Machin-
ing is one o he mos impo an manu ac u ing echnolo-
gies and ep esen s a majo ene gy demand [4]. To educe
i s ene gy consump ion, an unde s anding and es ima ion o
he ene gy consumed a e he p ima y and impo an s eps
[5]. The speci ic ene gy consump ion, ha is, he ene gy
equi ed o emo e he uni olume o a ma e ial, is an
impo an me ic o e alua ing he ene gy consump ion o
machining [6]. In e ms o he speci ic ene gy consump-
ion, g inding is one o he mos ene gy-in ensi e p ocesses
among o he me al cu ing ope a ions. Du ing g inding, he
la ges po ion o he emissions is a ibu ed o he ene gy
used o ma e ial emo al [7]. The g inding p ocess, which
emphasizes a high ma e ial emo al, is an ab asi e cu o
ope a ion, and is he sec ioning o ma e ials wi h hin
cu ing discs made o ab asi e pa icles [8,9]. The e o e, a
speci ic ene gy analysis o he g inding p ocess in ol ing a
high ma e ial emo al is ex emely impo an .
The speci ic ene gy consump ion om g inding has
h ee componen s: chip o ma ion ene gy, plowing ene gy
om he ma e ial de o ma ion, and sliding o ubbing
ene gy [10]. Rubbing o sliding is he i s s age o g ain
in e ac ion wi h he wo kpiece, and he elas ic de o ma ion
occu s du ing his phase wi h a negligible amoun o
ma e ial emo al. Wi h he inc ease in o ce, g ain pene-
a ion in o he wo kpiece also inc eases, leading o he
plowing phase, and bo h elas ic and plas ic de o ma ions
occu du ing his phase. Fu he pene a ion o g ain leads
&Muhammad Rizwan Awan
[email p o ec ed]
1
Depa men o Mechanical Enginee ing, Uni e si a
Poli e
`cnica de Ca alunya (UPC), Ba celona, Spain
2
Depa men o Elec ical Enginee ing, Uni e si a Poli e
`cnica
de Ca alunya (UPC), Ba celona, Spain
123
Ad . Manu .
h ps://doi.o g/10.1007/s40436-021-00361-2
o he cu ing phase, whe e he ma e ial is plas ically
de o med o p oduce chips [11,12]. In his pape , he
no a ions P
sl
,P
pl
, and P
ch
a e used o e e o he powe
consumed by he h ee mechanisms men ioned abo e, ha
is, sliding, plowing, and cu ing ene gy, espec i ely.
Va ious ac o s such as he ab asi e sha pness, ma e ial
p ope ies, and p ocess pa ame e s go e n he ansi ion o
ene gy consump ion beha io among hese h ee s ages and
ha e been ex ensi ely discussed. Acco ding o Rowe [13],
ubbing o sliding is he p edominan o m o ene gy in
ma e ial emo al o p ocesses such as polishing and lap-
ping, whe eas p ecision g inding occu s in all h ee
egimes. High-ene gy deep g inding and cu -o ope a ions
ake place p edominan ly in he ma e ial emo al egime
h ough a chip o ma ion o duc ile ma e ials o h ough a
c ack o ma ion o b i le ma e ials. Na
´poles e al. [14]
de eloped a ma e ial emo al a e model o e alua e he
speci ic ene gy consump ion du ing indus ial-scale g ind-
ing o C45K wi h di e en he mal ea men s and AISI
304. I was demons a ed ha he sliding ene gy was he
main o m o ene gy dissipa ion and dec eased wi h an
inc ease in he dep h o he cu . Masoumi e al. [15]
in es iga ed he ma e ial emo al beha io du ing su ace
g inding o a high- eloci y oxy- uel (HVOF) he mally
sp ayed WC-10Co4C coa ing. The esul s e ealed ha
ma e ial emo al was due o bo h a b i le ac u e and
duc ile low modes depending on he g inding pa ame e
a ia ion, and a la ge amoun o ene gy was dissipa ed by a
plas ic de o ma ion om he plowing. Simila ly, Singh
e al. [16] ound a speci ic plowing ene gy o be he mos
signi ican componen a lowe eed a es o he g inding
o ha d and high-s eng h ma e ials. Shaw [17] demon-
s a ed ha li le ene gy was ca ied by he chips when
conduc ing inish and o m g inding (FFG), whe eas wi h
s ock emo al g inding (SRG), mos o he speci ic ene gy
was consumed as he shea cu ing ene gy o p oduce chips.
Acco ding o Malkin and Joseph [18], a ex emely high
ma e ial emo al a es, he sliding and plowing ene gy
became negligible, and he minimum ene gy was equal o
he speci ic chip o ma ion ene gy. The minimum ene gy
equi ed o o m he chips is cons an , and a highe
emo al a es, i is he only dominan ene gy [6].
Con a y o many di e en s udies on he speci ic ene gy
o FFG, he speci ic ene gy consump ion o an ab asi e
cu o ope a ion wi h hin cu ing discs o me als has
a ely been discussed. In an ea lie s udy, Shaw e al. [19]
analyzed he in luences o he eed a e on speci ic ene gy
consump ion and cu ing o ces in an ab asi e cu o
ope a ion o s eel and aluminum. They used a cu ing disc
wi h a la ge diame e (508 mm) and an ex emely high eed
a es (3.39–12.7 mm/s) o he expe imen . The esul s
e ealed ha he cu ing o ces inc eased wi h an inc ease
in he eed a e up o some ex en and hen dec eased om
he end line. The speci ic ene gy consump ion dec eased
wi h an inc ease in he eed a e, howe e , his s udy did
no explain he h ee speci ic ene gy componen s o ub-
bing, plowing, and cu ing du ing ma e ial emo al.
Tu che a [20] in es iga ed he cu ing condi ions ha
a ec ed he cu ing o ce and cu ing ene gy in s one cu -
ing using diamond cu ing disks. The au ho showed ha
he cu ing ene gy dec eased wi h an inc ease in he dep h
o he cu and he eed a e, howe e , he cu ing o ce
inc eased wi h an inc ease in he equi alen chip hickness.
The adop ed model o he speci ic ene gy in his s udy did
no explain he ma e ial emo al phases and hei co e-
sponding ene gy componen s.
In all p e ious s udies measu ing he speci ic ene gy
consump ion om he g inding and ab asi e cu ing o
me al, s one, and op ical glass [6,19–22], he cu ing powe
(P) is measu ed in e ms o he angen ial o ces (F
) and
cu ing eloci y (V
c
) o he disc, and shown as
P¼F Vc:ð1Þ
This s udy aims o in oduce an al e na i e me hod o
di ec ly measu e he cu ing powe o a speci ic ene gy
e alua ion o an ab asi e cu o ope a ion. This me hod-
ology uses a combina ion o analy ical me hods and spe-
cially designed and manu ac u ed equipmen o au oma e
he mo emen o a s anda d g inde a di e en eed a es.
In addi ion, pa icula ly in s udies o ab asi e cu ing
ope a ions, he speci ic ene gy has no been dis inguished
in o h ee modes du ing ma e ial emo al [19,23]. How-
e e , in his esea ch, he speci ic ene gy measu ed h ough
an al e na i e me hod is ca ego ized in o h ee modes, i.e.,
sliding, plowing, and cu ing, using an empi ical model.
These h ee componen s used in g inding ha e been dis-
cussed in he li e a u e e iew because g inding also
in ol es me al cu ing wi h ab asi e discs and has been
ex ensi ely discussed and analyzed. The esea ch p esen ed
below will help unde s and how he ma e ial p ope ies and
cu ing condi ions a ec he beha io o he speci ic ene gy
consump ion du ing he ma e ial emo al.
2 Ma e ials and me hodology
2.1 Wo kpiece ma e ial and cu ing ool
The ma e ials used in his expe imen we e S235JR, C45K,
and e ous aluminum-based in e me allic alloy FeAl
(40%) wi h a chemical composi ion o 60% Fe and 40% Al
[24]. C45K was s udied in h ee di e en s a es: no mal
C45K condi ion, C45K wi h quenching (C45K-Q), and
C45K wi h quenching and empe ing (C45K-Q?T). The
chemical composi ions o S235JR and C45K a e lis ed in
Table 1[25,26].
M. R. Awan e al.
123
The ha dness o ma e ials (HRB) gi en in Table 2is
measu ed using a Rockwell ha dness es e (de eloped by
Wilson) wi h an inden e load o 100 kg. The ab asi e
cu ing ac ion is conduc ed using an ul a- hin s eel cu ing
disc wi h a 1 mm hickness, 22 mm bo e diame e , and 115
mm ou e diame e moun ed on a 600 W Ryobi g inde .
The echnical cha ac e is ics o he cu ing disc a e de ined
by he code 41 99A 46 S7 BF gi en in he ca alog [27]. The
i s digi code 41 indica es he manu ac u e symbol; 99A
indica es ha he ab asi e ma e ial is made o aluminum
oxide; 46 indica es a medium ha d g ain size; S7 is he
ha dness; and BF ep esen s a ype o esin used o
bonding. The ab asi e ma e ial o he cu o disc wi h a
coa se g ain size and high ha dness enables a as cu ing
[28,29].
2.2 Me hodology
The speci ic ene gy consump ion is he powe equi ed o
emo e he uni olume o ma e ial, and i s alue (V
SEC
)is
de ined as he a io be ween he powe consumed and he
ma e ial emo al a e, and shown as [6]
VSEC ¼Pm
Qw
;ð2Þ
whe e P
m
is he mechanical cu ing powe , and Q
w
is he
ma e ial emo al a e. To measu e he mechanical cu ing
powe , wo di e en expe imen al se ings we e applied
du ing he p ocess, as shown in Fig. 1. In he i s se ing, as
shown in Fig. 1a, he s anda d angle g inde was coupled
wi h a dynamome e o measu e and de e mine he ela-
ionship be ween he mechanical powe and elec ical
powe consumed unde di e en loading condi ions. The
Hys e esis Dynamome e , model HD-710-BNA, de eloped
by Mag ol, USA, was used o his expe imen . A high-
speed p og ammable con olle a ached o he
dynamome e displays he measu emen o mechanical
cha ac e is ics such as o que, mechanical powe (P
m
),
speed o o a ion ( /min), and elec ical cha ac e is ics such
as he e ec i e elec ic powe (E
e
) and ol age.
The a e age o e ec i e elec ic powe E
e
is he amoun
capable o ans o ming he elec ical ene gy in o wo k.
Pa o he dynamome e equipmen measu es he e ec i e
elec ic powe . This de ice does his by mul iplying he
cu en and ol age ins an aneously using a 4-quad an
mul iplie , and hen a e ages he ins an aneous powe
signal. The mechanical powe (P
m
) is de ined as he p o-
duc o he o que and angula eloci y. The ela ionship
be ween he mechanical powe (P
m
) deli e ed by he
g inde and he e ec i e elec ic powe (E
e
) consumed by
he mo o is shown in Fig. 2.
Pm¼2:4Ee742:61:ð3Þ
The beha io o his eg ession cu e is associa ed wi h
he g inde used and is he e o e an expe imen al esul o
he beha io o he equipmen used. The end line be ween
hese wo pa ame e s is linea . Equa ion (3) is a eg ession
equa ion o his end line, and 2.4 deno es he slope o he
line. Equa ion (3) ob ained h ough his g aph is pa icula
o his g inde and can be used o de e mine he mechanical
powe du ing me al cu ing wi h an ab asi e disc o
epe i i e expe imen s. Using he eg ession equa ion o
measu e he mechanical powe h ough he elec ical
ene gy consumed du ing ab asi e cu ing wi h a disc
elimina es he need o measu e he cu ing o ce and cu ing
eloci y o speci ic ene gy es ima ion. In he second s ep,
a s anda d angle g inde is moun ed on he expe imen al
con igu a ion, which has been speci ically designed and
manu ac u ed o moun and ope a e he s anda d disc
g inde a a ious eed a es o he me al ab asi e cu ing
ope a ion s udied he ein. Figu e 1b illus a es he di e en
pa s o he equipmen de eloped o his s udy. An ul a-
hin disc o 1 mm, moun ed on he angle g inde , ac ed as a
cu ing ool o machine he me allic ba s. The s eppe
mo o ope a es he machine a ou di e en eed a es
de ined by he po en iome e . The LED ligh s we e used as
indica o s o ou de ined speeds. Two e ical sepa a e
bu ons we e placed o he clockwise and an iclockwise
mo emen o he s eppe mo o , which e en ually mo ed
he machine up and down.
A schema ic diag am o he elec ical componen s inside
a wooden box is shown in Fig. 3. Owing o machine
equi emen s o highe accu acy in mo emen , posi ion-
ing, and a ying o que in dynamic loading, a s eppe
mo o was selec ed [30]. The speed, mo emen , and
di ec ion o he s eppe mo o in ela ion o he inpu eed
a e we e p og ammed using he A duino Uno mic ocon-
olle . The s eppe mo o d i e TB6600 con ols he cu -
en be ween he s eppe mo o and con ol ci cui in mic o-
Table 1 Chemical composi ion o me allic alloys
Me allic alloys C Mn P S Si Ni C
C45K 0.5 0.50–0.90 0.03 0.04 0.40 0.40 0.40
S235JR 0.22 1.60 0.05 0.05 0.05
Table 2 Ma e ial ha dness
Me allic alloys HRB
C45K 100.20
C45K-Q 120.60
C45K-Q?T 85.85
S235JR 80.05
In e me allic 100.20
Expe imen al echnique o analyze he in luence o cu ing condi ions on speci ic ene gy consump ion…
123
s eps. The eed a e ange can be changed by changing he
numbe o s eps in he d i e. G inde bu ons, eme gency
s op bu ons, and limi swi ches a e con olled h ough a
swi ch elay. Limi swi ches a e p og ammed wi h a
mic ocon olle , which s ops he s eppe mo o once he
mo emen eaches he maximum upwa d o minimum
downwa d limi on he lead sc ew. The powe sou ce is
used o s ep he inpu ol age supply down o 12 V o he
s eppe mo o d i e and o he unc ions.
The elec ical ene gy consumed by he machine du ing
he cu ing o ope a ion is measu ed using a powe ana-
lyze a di e en eed a es, which is s o ed in a compu e
h ough a channel eco de . Using hese elec ical ene gy
Fig.1 Expe imen al se up o measu e he mechanical powe and speci ic ene gy consump ion
M. R. Awan e al.
123
alues, he co esponding alues o he mechanical powe
a e calcula ed using he eg ession line in Eq. (3).
To measu e he ma e ial emo al a e in Eq. (2), a
gene al model o he ma e ial emo al a e o his expe -
imen has been used, which is he p oduc o he eed a e
and cu ing c oss sec ion [31], and shown as
Qw¼AcV ;ð4Þ
whe e V
is he eed a e, and A
c
is he cu ing c oss-sec ion.
V
in Eq. (4) is a unc ion o he o a ional speed o he
s eppe mo o . A kinema ic s udy o he spa ial mo emen
o he cen e poin , whe e he cu ing disc was moun ed,
was ca ied ou using gene alized coo dina es [32]. The
kinema ic s udy showed ha gi en a cons an o a ion
speed o he s eppe mo o , he eed a e a he cu ing poin
was e ical and emained cons an h oughou he cu ing
c oss sec ion. The eed a e alues ob ained om he
kinema ic s udies we e e i ied by he ime aken o he
cu ing discs o cu h ough he leng h o he wo kpiece.
The cu ing c oss-sec ion A
c
, shown in Eq. (4), is pe pen-
dicula o he eed a e, and is de ined by he p oduc o
ma e ial hickness ‘‘b’’ and wid h o cu ing hickness ‘‘a’’,
as shown in Fig. 4. The wid hs o he specimens we e 3, 10
and 4.6 mm o S235JR, C45K, and in e me allic Fe-Al
(40%), espec i ely, and he cu ing hickness was 1.8 mm.
The cu ing hickness was ound o be highe han ha o
he cu ing disc. I was e i ied ha he ac ual hickness o
he cu ing did no coincide wi h he in o ma ion p o ided
by he manu ac u e o a 1 mm hick cu ing disc. I was
also de e mined ha an axial de ia ion o he cu ing disc
occu ed when o a ed unde ee cu ing condi ions. The
eed a es used in his expe imen we e high o hese ypes
o discs. The e o e, du ing he ma e ial cu ing, a u he
bending and ib a ion o he cu ing disc inc eased he
cu ing hickness.
2.3 Measu emen o expe imen al da a
The elec ical ene gy consumed du ing he p ocess was
measu ed wi h an analog powe analyze buil wi h an
AD633 chip, which p o ided he ins an aneous p oduc
alues o he cu en and ol age. A channel eco de
logge Velleman K8047 connec ed o a compu e allows
collec ing he powe signal wi h a sampling equency o
0.01 s. Figu e 5shows he powe cu e o a cu ing
expe imen on S235JR ma e ial wi h V
a 1.488 mm/s.
The beha io obse ed du ing all expe imen s was
simila and could be di ided in o h ee s ages. The i s
s age co esponds o he ene gy consump ion when he disc
is no cu ing. The second s age is he ansi ion s age in
which cu ing begins, cha ac e ized by a apid inc ease in
he cu ing powe . The hi d s age is he s abiliza ion s age
o he powe consump ion. The a e age powe consumed
du ing he las s age, E
e
, is used o es ima e he speci ic
ene gy consump ion. Using he eg ession in Eq. (3), P
m
is
ob ained as a unc ion o he measu ed E
e
. The cu ing
hickness o each specimen was measu ed using a WADEO
iT33-MDUK digi al mic oscope wi h a 2 Mega pixel image
senso . The hickness was measu ed using Image J2 open-
sou ce so wa e o a scien i ic image analysis, de eloped
by he Uni e si y o Wisconsin-Madison. The wid h o he
specimen was measu ed wi h a digi al e nie calipe . The
Fig. 2 Mechanical powe e sus elec ical ene gy
Fig. 3 Schema ic diag am o elec ical ins umen s Fig. 4 Cu ing c oss sec ion
Expe imen al echnique o analyze he in luence o cu ing condi ions on speci ic ene gy consump ion…
123

equipmen allowed he selec ion o ou di e en eed a es
p e iously se a 0.539, 0.613, 0.899 and 1.488 mm/s.
Owing o he p obabili y o a lack o uni o mi y in he g ain
alignmen o he wo kpiece ma e ial and cu ing disc, and a
small la e al ib a ion o he cu ing disc a lowe eed
a es, a small change in he ma e ial emo al a e was
ound o he same eed a e. To compensa e o his, he
cu ing expe imen was epea ed ou imes o each eed
a e.
The sliding powe (P
sl
) was measu ed h ough a sepa a e
expe imen , as shown in Fig. 6. The cu ing disc is engaged
wi h he wo kpiece ma e ial a a speci ic eed a e. When
he cu ing disc eached he middle o he cu ing pa h and
he powe consump ion was s abilized, he eed a e was
s opped a poin A, wi h he cu ing disc main ained in he
unning condi ion. S opping he eed a e p oduced a sud-
den d op in powe , which was again s abilized a poin P.
This ope a ion kep he cu ing disc in con ac wi h he
ma e ial wi hou chip emo al and wi hou p oducing a
plas ic de o ma ion. The powe measu ed a he in e sec-
ion poin P o eg ession lines BC and DE was only
associa ed wi h he sliding phenomenon.
2.4 Cu ing model
The cu ing model is based on he ac ha he mechanical
powe consumed by cu ing (P
m
) is equal o he summa ion
o he powe consumed by sliding (P
sl
), powe consumed
by plowing (P
pl
), and powe consumed by he chip o -
ma ion (P
ch
), and shown as
Pm¼Psl þPpl þPch:ð5Þ
The ela ionship be ween he speci ic cu ing ene gy and
ma e ial emo al a e shown in Figs. 7and 8is es ima ed
by he empi ical model, and shown as
PmPsl
Qw
¼Ppl
Qw
þVSCE:ð6Þ
The model p esen ed in Eq. (6) was p oposed by
Gu owski e al. [33] and la e alida ed by Ka a and Li [34]
based on expe imen al esul s. The adop ed model
demons a ed s a is ical accu acy in e alua ing he speci ic
ene gy consump ion wi h espec o he ma e ial emo al
a e o he p ocesses o g inding, milling, u ning, and
injec ion molding [35]. The expe imen al alues o speci ic
ene gy consump ion o he C45, in e me allic Fe-Al(40%),
and S235JR a e shown in Figs. 7and 8, espec i ely. This
was e i ied h ough he p oposed model in Eq. (6). The
powe s dissipa ed by P
sl
,P
pl
and speci ic cu ing ene gy o
a ma e ial a e cons an , as shown in Table 3. These con-
s an alues o P
pl
and speci ic cu ing ene gy a e he
coe icien s o Eq. (7) and used o d aw he expe imen al
g aphs in Figs. 7and 8. These coe icien s we e ob ained
by adjus ing he expe imen al da a using he leas squa es.
Figu es 7and 8indica e ha he beha io o his model is
asymp o ic. Wi h an inc ease in he ma e ial emo al a e,
he a io o P
pl
o Q
w
dec eases, and a an ex emely high
ma e ial emo al a e, he plowing ene gy educes signi i-
can ly. The educ ion in he plowing ene gy in e ms o
Fig. 5 Elec ical ene gy consump ion beha io
Fig. 6 Sliding powe measu emen o C45K-Q?T
M. R. Awan e al.
123
pe cen age is also shown in Fig. 10. The educ ion o
plowing ene gy wi h he ma e ial emo al a e is in
ag eemen wi h p e ious esea ch on g inding [6,14]. The
sliding powe depends on he o a ional speed o he cu ing
disc. In his expe imen , he o a ional speed o he cu ing
disc is cons an and unde goes an ex emely small change
depending on he eed a e. The e o e, he sliding powe
emains cons an . The eg ession applied o he expe i-
men al da a o he ma e ials has coe icien s o eg ession
R
2
g ea e han o equal o 0.872. The coe icien o
de e mina ion, close o uni y o mos o he ma e ials,
shows a good i be ween Eq. (6) and he expe imen al da a
o he speci ic ene gy consump ion.
3 Resul s and discussion
A single ac o one-way analysis o a iance (ANOVA)
was applied o he mean speci ic ene gy alues o he ou
eed a es, as shown in Table 4. The a ia ions in he mean
alues o he speci ic ene gy consump ion we e s a is ically
signi ican (P alues o less han 0.05) o mos o he
ma e ials. The e o e, he eed a es used o p oduce di -
e en ene gy consump ions do no belong o he same
amily o cu ing condi ions.
In gene al, o all ma e ials, he speci ic ene gy con-
sump ion dec eases asymp o ically wi h an inc ease in he
ma e ial emo al a e, which con i ms he accu acy o he
adop ed me hodology. I is e iden om he g aphs in
Figs. 7and 8 ha , a an ex emely small ma e ial emo al
a e, he speci ic ene gy consump ion is qui e high. This
phenomenon is known as he size e ec [6]. Wi h an
inc ease in he ma e ial emo al a e, he speci ic ene gy
consump ion dec eases. Because he speci ic ene gy con-
sump ion o a ma e ial de o ma ion has a cons an alue,
Fig. 7 Speci ic ene gy consump ion ela ionship wi h ma e ial
emo al a e o C45K, C45K-Q?T, C45K-Q
Fig. 8 Speci ic ene gy consump ion ela ionship wi h ma e ial emo al a e o aS235JR and bin e me allic Fe-Al(40%)
Table 3 Asymp o ic pa ame e alues and sliding powe
Ma e ials P
sl
/
(Js
-1
)
P
pl
/
(Js
-1
)
VSEC /
(Jmm
-3
)
R
2
S235JR 29.16 163.69 37.50 0.956
In e me allic-
FeAl(40%)
77.36 113.19 13.08 0.878
C45K-Q 99.36 228.04 7.82 0.912
C45K-Q?T 117.36 216.21 4.93 0.923
C45K 127.36 152.18 4.16 0.872
Expe imen al echnique o analyze he in luence o cu ing condi ions on speci ic ene gy consump ion…
123
his dec ease in he speci ic ene gy consump ion is only
due o he dec ease in he plowing ene gy ( Ppl
Qw). Thus, a a
highe s ock emo al a e, he speci ic ene gy consump ion
is educed o he minimum alue.
This minimum ene gy is he speci ic cu ing ene gy,
which emains cons an h oughou he en i e cu ing p o-
cess, as con i med by Malkin and Guo [6]. Acco ding o
Shaw [17], in he s ock emo al g inding p ocess, mos o
he ene gy was dissipa ed as he shea cu ing ene gy
equi ed o p oduce he chips. Howe e , he au ho con-
duc ed an ab asi e cu ing o ope a ion a ex emely high
eed a es (5–60 /min o 2.1–25.4 mm/s) [19]. The dom-
inance o he shea cu ing ene gy in hei expe imen s was
a ibu ed o he use o ex emely high eed a es. The ange
o eed a es du ing his expe imen (0.5–1.488 mm/s) is
low in compa ison o he eed a es used by Shaw [17]. The
gi en eed a es a e suppo ed by he g inde used, and eed
a es highe han his ange s opped he cu ing machine.
Lowe eed a es allowed he cu ing disc o su icien ly
de o m he ma e ial be o e b eaking, which was he eason
o he dominance o he plowing ene gy and he low
speci ic cu ing ene gy.
Figu e 7shows he ela ionship be ween he speci ic
ene gy consump ion and he ma e ial emo al a e o he
h ee ma e ials o no mal C45K and C45K wi h di e en
he mal ea men s. C45K-Q shows he highes speci ic
ene gy consump ion wi h he highes ha dness, ollowed by
C45K-Q?T wi h he lowes ha dness. C45K has he lowes
speci ic ene gy consump ion among he h ee ma e ials,
al hough i s ha dness is highe han ha o C45K-Q?T.
The speci ic ene gy consump ion o hese h ee ma e ials
and hei co ela ion wi h he ma e ial ha dness exhibi a
di e en end om he p e ious esea ch conduc ed by
Na
´poles e al. [14] on he same ma e ials o su ace
g inding. The mal ea men signi ican ly a ec ed he
speci ic ene gy consump ion and speci ic ene gy con-
sump ion o he ma e ials. The speci ic ene gy consump-
ion o C45K-Q s eel is he highes among he h ee
specimens o C45K owing o i s high ha dness. Ma inescu
e al. [36] epo ed ha an inc ease in ha dness inc eased
he esis ance o ab asi e machining, he eby inc easing he
cu ing o ces and machining di icul y. C45K empe ed
s eel consumes a highe speci ic ene gy compa ed wi h
C45K despi e he low ha dness owing o he empe ing
conduc ed o educe he ha dness and inc ease he ough-
ness and duc ili y o he ma e ial [37]. An inc ease in
oughness inc eases he ene gy equi ed o de o m he
ma e ial [38]. The h ee ma e ials show he same end o
dec ease in he speci ic ene gy consump ion.
Howe e , o quenched and empe ed s eel, a a high
ma e ial emo al a e, he machine did no p o ide an
accu a e ep esen a ion o he ene gy consumed, and he
cu ing disc was jammed in o he wo kpiece. This indica es
ha he mal ea men has a conside able e ec on he
machinabili y o he ma e ials. I also shows ha his cu ing
disc has limi a ions o speci ic ma e ials unde ce ain cu -
ing condi ions. The mal ea men o C45K also a ec s he
speci ic cu ing ene gy. As shown in Table 3, C45K, C45K-
Q?T, and C45Q exhibi conside able di e ences in he
alues o speci ic cu ing ene gy. Howe e , acco ding o
Malkin and Joseph [18], he minimum ene gy equi ed o
p oduce chips in he ab asi e p ocess is una ec ed by
alloying o hea ea men . Thus, he di e ence in he speci ic
cu ing ene gy owing o he hea ea men o C45K used in
his expe imen is no in ag eemen wi h Re . [18].
Among he me allic alloys, S235JR, which has he
lowes ha dness, had he highes speci ic ene gy con-
sump ion and speci ic cu ing ene gy, as shown in Fig. 8a.
The ca bon con en o S235JR is compa a i ely lowe
among specimens, and low ca bon s eel is mo e duc ile.
Thus mo e ene gy is equi ed o machine he low-ca bon
s eel in compa ison o he medium-ca bon s eel and is
compa a i ely di icul o machine [39]. In compa ison o
b i le ma e ials, duc ile ma e ials unde go ex ensi e plas-
ic de o ma ion be o e ac u e [40]. A la ge amoun o
plas ic de o ma ion in duc ile ma e ials equi es a high
speci ic ene gy o ac u e he ma e ial [41,42]. The e o e,
he high alues o speci ic ene gy consump ion and speci ic
ene gy consump ion o S235JR a e a ibu ed o a la ge
plas ic de o ma ion owing o a high duc ili y.
The speci ic ene gy consump ion beha io o he in e -
me allic Fe-Al(40%) is shown in Fig. 8b. The ha dness o
me allic Fe-Al(40%) is he same as ha o C45K, and i s
speci ic ene gy consump ion ela ionship wi h ma e ial
emo al ollows he same end as ha o he no mal
C45K. C45K is b i le owing o i s highe ca bon con en .
The same end o expansion is a ibu ed o he b i le
na u e o he in e me allic Fe-Al (40%). The b i le ac u e
o in e me allic ma e ials is due o weak g ain bounda ies
and he highe concen a ion o aluminum, which limi s he
duc ili y o he ma e ial [24,43,44]. Howe e , he speci ic
Table 4 One way ANOVA
Sou ce SS d MS FP- alue F-
c i ical
C45K 326.49 3 108.8 75.784 3.68 9
10
-5
4.757
C45K-
Q?T
147.3 2 73.65 4.4783 0.06456 5.143
C45K-Q 343.13 2 171.6 26.736 0.001027 5.143
Fe-
Al(40%)
941.94 3 314 24.823 0.000418 4.347
S235JR 80.468 3 26.823 57.243 9.49 9
10
-8
3.411
M. R. Awan e al.
123
ene gy consump ion o in e me allic Fe-Al (40%) is highe
han ha o he C45K no mal and wi h he mal ea men .
As shown in Table 3, he speci ic cu ing ene gy o in e -
me allic Fe-Al (40%) in pe cen age o o al ene gy is
highe han ha o no mal C45K and wi h he mal ea -
men . This indica es he compa a i ely sligh ly highe
duc ili y o in e me allic Fe-Al(40%), which is he eason
o he high speci ic cu ing ene gy. Saigal and Yang [45]
also epo ed highe cu ing o ces o i on aluminides in
compa ison o medium-ca bon s eel o milling ope a ions.
Figu e 9shows a compa ison o he sliding powe pe
uni o cu ing a ea o all ma e ials. The expe imen esul s
in Fig. 6show ha he sliding ene gy does no pa icipa e
in he ma e ial emo al p ocess and is me ely a ubbing o
ic ion ene gy. Fo his eason, sliding powe pe uni o
cu ing a ea was used by Zhang e al. [46] and Linke e al.
[47]. The highes alue o he sliding powe pe uni cu ing
a ea o in e me allic Fe-Al(40%) was due o i s b i le
na u e a no mal empe a u es. The sliding o ubbing
powe is dissipa ed du ing he ini ial con ac o he cu ing
g ain wi h he ma e ial, and does no p oduce a ma e ial
de o ma ion. B i le ma e ials do no unde go any plas ic
de o ma ion be o e a ac u e [31]. The e o e, he high
sliding powe o in e me allic Fe-Al(40%) is due o he
ini ial ubbing ene gy being abso bed by he ma e ial
wi hou p oducing plas ic de o ma ion. Wu e al. [48]
p esen ed a model ha also p o ided some suppo o his
a gumen , which s a ed ha , in he g inding o b i le
ma e ials, he main o ms o ene gy dissipa ion we e ub-
bing and chipping. S235JR has he highes duc ili y among
he gi en ma e ials, and duc ile ma e ials end o unde go
signi ican plas ic de o ma ion p io o a ac u e [40].
The e o e, he plas ic de o ma ion o S235JR s a s ex e-
mely ea ly, which is he eason o he e y low sliding
powe dissipa ion pe uni cu ing a ea. The C45K amily
has a lowe duc ili y han S235JR owing o i s highe
ca bon con en , which is he eason o he compa a i ely
highe sliding ene gy pe uni o he cu ing a ea. Wi hin
he C45K amily, C45K-Q has he highes ha dness, which
inc eases he b i leness, and hus, he sliding powe pe
uni o he cu ing a ea inc eases. C45K-Q?T has less
sliding powe pe uni o cu ing a ea han C45K because o
he he mal ea men . As he empe ing educes he ha d-
ness and inc eases he duc ili y o he ma e ial, he sliding
powe pe uni o cu ing a ea is educed.
To de e mine he pe cen age o con ibu ion o he
speci ic ene gy componen s o ma e ial emo al, he ba
cha shown in Fig. 10 was d awn. The sliding ene gy is no
shown in his g aph because i me ely ubs and does no
de o m he ma e ial. Fo all ma e ials, in gene al, he
speci ic plowing ene gy has been ound o be he mos
signi ican phenomenon in he o al speci ic ene gy con-
sump ion. The dominance o he plowing ene gy o hese
ma e ials is due o he use o a compa a i ely low eed a e
o his expe imen . The con ibu ion o he plowing ene gy
in e ms o he pe cen age is highe o he C45 K amily o
ma e ials because o hei high ha dness alues. E en a
high eed a es, plowing ene gy emained he mos domi-
nan phenomenon, wi h 68%, 79%, and 73% o C45K,
C45K-Q?T, and C45K-Q, espec i ely. The dominance o
he plowing ene gy in ha d and high-s eng h ma e ials has
also been de e mined o g inding [16,49]. The con ibu-
ion o speci ic ene gy consump ion in e ms o pe cen age
was compa a i ely highe o S235JR a highe eed a es.
Owing o he low ha dness alue o S235JR, he ansi ion
om elas ic o plas ic de o ma ion becomes easie a highe
eed a es, which apidly educes he plowing ene gy.
The cu ing powe depends on he ma e ial p ope ies
and eed a e. The ela ionships be ween he cu ing powe
and he eed a es o C45K and S235JR a e shown in
Fig. 11. As indica ed in Fig.11, he cu ing powe inc eases
wi h an inc ease in he eed a e; howe e , a a ce ain
highe eed a e, he inc ease in cu ing powe educes and
he cu e ends o la en. A high eed a es, he cu ing
g ains become sha pe and consume less powe o me al
cu ing; hence, he cu ing o ce dec eases. This beha io is
analogous o he esea ch indings o Shaw [19] on ab asi e
cu o ope a ions. The cu ing powe ela ionship wi h he
eed a e o in e me allic Fe-Al(40%) did no ollow he
gene al end. As shown in Fig. 11, he cu ing powe a a
high eed a e did no dec ease and inc eased o a highe
alue. This inc ease in cu ing powe is a ibu ed o an
inc ease in he duc ili y o he ma e ial owing o he high
empe a u e encoun e ed a high eed a es. A high eed
a es, an inc ease in empe a u e inc eases he yield s ess;
hence, he duc ili y o in e me allic Fe-Al(40%) inc eases
Fig. 9 Compa ison o sliding powe pe uni o cu ing a ea o all
ma e ials
Expe imen al echnique o analyze he in luence o cu ing condi ions on speci ic ene gy consump ion…
123