Optimizing Cutting Conditions in Single Pass Face Milling for Minimum Cutting Energy, Time, Cost, and Surface Roughness

Technology evolution and the demand of modern life have led to more using for machine tools which are the basic energy consumption devices in manufacturing. Subsequently, CO₂ emissions in the atmosphere will increase, causing several climate changes such as the greenhouse effect. As the resources and energy in the earth are limited and getting fewer and fewer, sustainable manufacturing is gaining more and more attention to produce the same product with less negative environmental impacts. In this paper, a mono-objective optimization for sustainable manufacturing is presented. Such approach needs a balance between economic and ecological aspects. Thus, the objective of this work is machining product with less environmental impacts by minimizing consumed energy with respect to technological and economic constraints. The consumed energy is modelled based on the dynamic behavior of the cutting forces. A case study of single pass of face milling operation is carried out using the particle swarm optimization tool. The surface quality is adopted as an objective in this work. Three decision variables are taken into account during the resolution such as rotational speed, axial depth of cut and feed per tooth. Results show that the proposed optimization model has a great efficiency to find a trade-off between the four objective functions in order to minimizing them.