Specific Energy Based Characterization of Surface Integrity in Mechanical Machining

In mechanical machining operations, process mechanisms and machining efficiency can be characterized by the cutting tool geometry, process parameters and workpiece materials. These variables are vital parameters to evaluating the specific cutting energy demand as indication to sustainable manufacture. In today's manufacturing environment, where minimum production cost is required to maximize profits, optimum performance of manufactured component is one of the pre-requisite to consumer's continuous patronage. The optimum performance of product especially in machining can be linked to process mechanisms, specific energy demand and surface roughness. Surface integrity is known to vary with values of the ratio of un-deformed chip thickness to cutting edge radius. The specific energy demand is influenced as process mechanism changes. This raises the economic cost of manufacture and CO2 emission. In this work, surface integrity of mechanically machined component is characterized and linked to its corresponding process mechanisms and specific energy demand. This work will contribute towards an improved process parameter selection for minimum energy demand, aid process planning, sustainable manufacture and resource efficiency for mechanical machining processes.