Cutting parameters used for the experiments.

Metal cutting has been extensively studied over the years for improving its efficacy, yet, parasitic mechanisms like chatter and tool wear continue to generate higher forces and energy consumption with poor surface integrity. To address these parasitic mechanisms, a single-point turning cutter design is proposed based on the physics-of-machining including chatter theory to achieve reduced power consumption during the cutting of various metallic alloys like Al-6061, Ti-6Al-4V and others used by critical sectors such as aerospace and automotive. The current work focuses on aspects of machining that effectively reduce parasitic forces feeding into cutting power. The proposed cutter amalgamates features such as optimum side and end cutting edge angles, smaller nose radius and textured rake face into the cutter-body. Such a design is further proposed for use with a mechanochemical effect on a recently discovered plastic flow mode called sinuous flow, which has been reported to bring down cutting forces significantly. Experimental and analytical tests on the cutter design features validate reduction of cutting forces and through that alleviate the tendency to chatter as well as bring about energy savings for cutting of Al 6061. The potential for reduced real-time power consumption makes this design-framework significant for multipoint milling cutters too. It will greatly facilitate frugal manufacturing to account for sustainability in manufacturing operations.