Austenitic stainless steel AISI 316L is used in many applications, including chemical industry, nuclear power plants, and medical devices, because of its high mechanical properties and corrosion resistance. Machinability study on the stainless steel is of interest. Toward sustainable manufacturing, this study also includes the power consumption during machining along with other machining responses of cutting force, surface roughness, and tool life. Turning on the stainless steel was performed using coated carbide tool without using cutting fluid. The turning was performed at various cutting speeds (90, 150, and 210 m/min) and feeds (0.10, 0.16, and 0.22 mm/rev). Response surface methodology was adopted in designing the experiments to quantify the effect of cutting speed and feed on the machining responses. It was found that cutting speed was proportional to power consumption and was inversely proportional to tool life, and showed no significant effect on the cutting force and the surface roughness. Feed was proportional to cutting force, power consumption, and surface roughness and was inversely proportional to tool life. Empirical equations developed from the results for all machining responses were shown to be useful in determining the optimum cutting parameters range.

Downsizing energy consumption during the machining of metals is vital for sustainable manufacturing. As a prerequisite, energy consumption should be determined, through direct or indirect measurement. The manufacturing process of interest is the finish turning which has been explored to generate (near) net shapes, particularly for hardened steels. In this paper, we propose using measured cutting forces to calculate the electrical energy consumption during the finish turning process of metals where typically the depth of cut is lower than the cutting tool nose radius. In this approach, the resultant cutting force should be used for calculating the energy consumption, instead of only the main (tangential) cutting force as used in the conventional approach. A case study was carried out where a hardened stainless steel (AISI 420, hardness of 47–48 HRC) was turned using a coated carbide tool, with a nose radius of 0.8 mm, without cutting fluid, and at 0.4 mm depth of cut. The experimental design varied the cutting speed (100, 130, and 170 m/min) and feed (0.10, 0.125, and 0.16 mm) while other parameters were kept constant. The results indicate that the electrical energy consumption during the particular dry turning of hardened steel can be calculated using cutting force data as proposed. This generally means machining studies that measure cutting forces can also present energy consumption during the finish or hard turning of metals, without specifically measuring the power consumption of the machining process. For this particular dry turning of hardened stainless steel, cutting parameters optimization in terms of machining responses (i.e., low surface roughness, long tool life, low cutting force, and low energy consumption) was also determined to provide an insight on how energy consumption can be integrated with other machining responses towards sustainable machining process of metals.

Machining process should also consider environmental aspect, with power consumption as one of the criteria. Cutting parameters can be optimized to minimize power consumption. This paper takes a study on turning of nickel-based hastelloy under dry condition (no cutting fluid) which varies cutting speed (150, 200, and 250 m/min) and depth of cut (0.5, 1.0, and 1.5 mm). Power consumption of particular machining process at various cutting parameters was derived and calculated. It was found that minimum power consumption was shown when the turning process was performed at the lowest cutting speed and depth of cut.

Machining companies can implement sustainable manufacturing using steps to improving the performance of economic, environmental and social. One of the steps is to perform the efficiency of energy consumption (mainly electricity) in machining. This paper describes a case study which investigates the effect of cutting parameters on power consumption and surface roughness by applying design of experiments. Dry turning of treated Al-11%Si alloy using coated carbide tool at different cutting speed (70, 130 and 250 m/min) and feed (0.05, 0.10 and 0.15 mm) was investigated. The results showed an optimum effect of cutting parameters that was obtained at low feed rate and high cutting speed, as shown by the model solutions.

The gears are an important part of a mechanism. Making gears requires high precision to avoid backlash. The machining process that can produce high precision is the process of Wire cut EDM. This study aims to determine the roughness of the workpiece surface and investigate the effect of current and wire speed on the roughness of the straight gear surface through wire cut machine EMS 45. The wire cut machining parameters used are 3, 5, and 7 amperes for current, and wire speed of 8, 10, and 12 mm/min. While the Wire material is a type of brass with 0.25 mm in diameter. The results presented that the increased use of current and wire speed will result in lower surface roughness, and vice versa. Therefore, it can be concluded that use low machine parameters to produce a smooth workpiece surface.

The springback is variably sensitive to materials and process parameters. Considering springback occurred in a formed part is significant for designing tools and dies. In this paper, experiments of a V-shape bending test were performed for investigating the springback effect. The punch parameters variation has been observed in ASTM A-36 mild carbon steel. Punch radius used and punch angle). The V-shape bending of mild steel was performed using Universal Testing Machine (UTM) at various punch radius (2, 4, and 6 mm) and punch angle (80°, 85°, and 90°) and at constant of die radius (10 mm) and die width (50 mm). The experimental result indicates that the punch radius has a most significant impact on springback behaviour of these sheet metal. This is verified through our experimental work using V-shape bend testing.