The manufacturing industry accounts for 23% of global energy consumption, with India
recording the highest rate of industrial energy consumption growth of 4% in 2010-18.
Machining is a manufacturing workhorse of the industrial sector and also a major energy
consuming process. The increasing demand for energy in these processes is a significant
environmental and economic challenge warranting the need to achieve minimal energy
consumption. Recent studies by several researchers have focused on this aspect, with most of
these efforts, based on the theoretical and empirical modelling methods or optimization of
cutting parameters using statistical analysis. However, there are limited studies of energy
efficiency of a machine tool cutter as one of the primary energy consumption devices while
achieving improved surface quality, form accuracy, increased throughput and longer tool life.
The problem of energy consumption can be streamlined at the root by focusing on the
mechanics underlying metal cutting operation to bring down parasitic energy dissipating
mechanisms in machining. It should be noted that parasitic mechanisms are energy
dissipators that lower the efficiency of metal-cutting processes. The current work aims to
explore the cutting zone of a new cutter in which shearing of work material to form a new
surface expends energy while focusing on suppression of tool-wear and chatter, a self-excited
vibratory parasitic phenomenon, occurring due to interaction between dynamics of the metal
cutting process and the machine-tool structure. The design and development of such a cutter
will streamline turning operation and intrinsically take care of the associated higher energy
consumption along with other parasitic mechanisms to achieve overall energy efficiency,
thus, contributing towards sustainable manufacturing.