An investigation of cutting parameters effect on sound level, surface roughness, and power consumption during machining of hardened AISI 4140

In recent years, the necessity for energy in the manufacturing industry has become an important problem because fossil fuel reserves are decreasing in order to produce energy. Therefore, the efficient use of energy has become an important research topic. In this study, energy efficiency is investigated in detail for sustainable life and manufacturing. AISI 4140 material with high hardness of 50 HRC hardness has been applied cryogenic process to improve mechanical and machinability properties. In this experiment study, the effects of feed rate (0.04, 0.08, 0.12 mm/rev), cutting speed (140, 160, 180 m/min), depth of cut (0.05, 0.10, 0.15 mm) and tool radius (0.4, 0.8) on energy consumption, surface roughness and sound intensity were investigated. Then, a new mathematical model with high accuracy was developed. Total power consumption was calculated by considering the instantaneous current value and machining time. As a result, it is found that good surface quality obtained when the feed rate is low, and the tool radius is high and the machining time is shortened, the energy consumption is reduced due to the increase in cutting speed, depth of cut and feed rate. Also, it is found that the tool radius has a limited effect on energy consumption, but low feed value increases energy consumption.