The global trend for energy consumption as a foundational requirement for economic and social development is an increasing
one. Electricity consumption is proportional to the CO2 emitted at the process level and especially for machining processes. The electrical
energy demand during machining can be categorized and modelled as basic energy (energy demand by the machine tool while operating
at zero load) and tip energy (energy for actual material removal – cutting). The tool tip energy is evaluated from the specific cutting energy.
At present limited data exists with regards to the key parameters required for modelling the tip energy. Previous studies and data for
specific energy were based on the normalisation of the total energy demand with the material removal rate and have not investigated the
effect of tool wear. In this work, the impact of tool wear on the specific energy coefficients in machining were studied and modelled. Cutting
tests were performed and tool wear and tool life based on the specific energy coefficient for each wear land value were evaluated. The
study has for the first time provided data on the variation of specific cutting energy for higher tool wear lands and presents vital sensitivity
analysis. With longer cutting time, tool wear increases which leads to higher specific cutting energy and energy consumption during
machining. The specific energy coefficient increased by up to 50% when turning EN8 steel alloy between 2 and 10 passes. This knowledge
is vital information for process planners and could enable energy estimates to be more accurate and realistic with regards to capturing the
impact of tool wear
