Milling is the most common machining method, a material removal procedure by cutting away the unwanted material. During the process, the engagement between cutting tool and workpiece will cause the fluctuation of cutting force and consumption of cutting energy. The cutting energy consumed affected the power consumption of the production and indirectly increase the production cost. The tool engagement also has a big impact on machining performances such as chip formation, tool wear, and integrity of the machined surface. The study related to tool engagement focused more on the effect on cutting force. However, not much attention given on the study of the effect of tool engagement on cutting energy. Hence, this study is to explore how different tool engagement angle affected the cutting energy. In addition, the result of tool wear and surface roughness also will be analyzed. In this study the experiment was conducted by using AISI P20 tool steel and 2 flutes coated carbide end mill. Cutting speed, feed rate and depth of cut are remains constant during the machining process which are 250 m/min, 100 mm/min and 0.2 mm respectively. The tool engagement angle varies from 90°, 135° and 180°. The cutting energy, surface roughness and tool wear were measured. From the result, it shows that cutting energy and tool wear is directly proportional to the tool engagement while the surface roughness is inversely proportional to the tool engagement.
