Evaluation of Power Consumption in High Efficiency Milling (HEM) of Aluminium 6061

 In the machining industry, reducing energy consumption at a maximal material removal rate (MRR) has long been a priority. Using the response surface method, a predictive model has been proposed for the minimal power consumption in side-milling machining.  Using response surface method (RSM), the effect of cutting parameters (feed rate, spindle speed, and radial depth of cut) on power consumption was investigated. The results revealed thatfeed rateis the most influential parameter for power consumption. The higher feed rate, the shorter cycle time thus reduce the power consumption. Based on the optimization model, minimum power consumption of 82.38 kW can be achieved at feed rate = 6,000 mm/in, radial depth of cut of 0.3 mm and spindle speed 12,000 rpm.