###### Abstract  
The energy efficiency in metal cutting is, sometimes, very low. Recent studies show that the energy consumed for detaching chips represents only about 15% of the total energy involved in material machining. The available solutions for energy optimization in cutting processes mentioned are the improvement of manufacturing equipment, the optimization of processes, and appropriate production scheduling. Already-performed research shows that to increase energy efficiency, the cutting force must be reduced, for example, by reducing the depth of the cut and by increasing the feed rate. However, this is applicable when the cutting force is quasi-constant during the process, which is not the case for gear teeth cutting when the cutting force significantly varies. The present paper proposes a new solution for energy efficiency increase in gear teeth cutting, namely, the smoothing of the cutting force variation during the machining process, by keeping the area of the detached chip section quasi-constant during the cutting process. This can be reached by replacing the constant rolling feed, currently used in gear teeth cutting, with a rolling feed that varies after an appropriate law. An algorithm dedicated to implementing this solution has been developed. It uses graphical modeling in CATIA to find the variation in the detached chip area. Original MatLab R2018a applications were developed (i) to identify the analytical form of the law that approximates this variation and (ii) to find the variation law of the feed during the rolling motion, if imposing a constant area of the detached chip. The algorithm was successfully applied in the cases of footing with a rack tool (by slotting) and with a pinion cutter (by slotting and turning). A technical solution for method implementation in practice is also presented. g 2024 14 9751 10.3390/app14219751 10.  
changed. Producing electricity sustainably and energy efficiency have become top priorities on a worldwide scale, and the manufacturing domain is no exception. This study [3] has established a framework for energy performance improvement in manufacturing and subdivides the methods to be used for this purpose into four aspects: energy monitoring, evaluation, optimization, and benchmarking. Moreover, the available solutions for energy optimization are the improvement of manufacturing equipment, the optimization of processes and parameters, appropriate production scheduling, and a management system. In the part machining process, cutting parameters have a huge impact on energy and material consumption, cutting the time and economy of the manufacturing system. Many researchers have been engaged in energy-efficient cutting parameter optimization, and a significant amount of the dedicated literature has been published in recent years. For sampling, paper [4] presents a method for such optimization, aiming to balance cutting indexes, i.e., carbon emissions, cutting time and cutting cost, in the part machining process, by using non-cooperative game theory integrated NSGA-II. The article [5] shows an integrated model for machining energy consumption, designed to enable the use of the Simulated Annealing technique to find the optimal spindle rotation speed and feed rate that result in the minimum machining energy consumption by also considering the non-cutting energy consumption. Other research [6; 7; 8] approaches the same type of problem based on different energy models and optimization techniques. Paper [9] analyzes energy-efficient cutting parameter optimization using the experimental design method. Gears are the most common solution to transmitting rotation motion with power between mW and hundreds of kW in devices from the medical domain to heavy, energy-producing, or aircraft industries [10]. Naturally, there is a significant number of gears in worldwide machinery, among which one can find many types of gears and a certain number of shapes for tooth profiles, as well.