Reducing energy consumption in manufacturing is essential for using energy effectively and minimising carbon footprint. In this study, the equation for selecting optimum cutting conditions to minimise energy footprint was extended by considering the fact that as tool wear increases, power and specific energy also increase. This new model enables selecting optimum conditions for energy-smart machining by considering energy footprint, cutting tool utilisation and the volume of material to be removed. This timely research improves the integrity of energy models in machining and their suitability and impact in practical machining conditions.
