Identification of new material model for machining simulation of Inconel 718 alloy and the effect of tool edge geometry on microstructure changes

2012 ◽

Vol 227 (8) ◽

pp. 1761-1775 ◽

Cited By ~ 9

Author(s):

HZ Li ◽

J Wang

Keyword(s):

Cutting Forces ◽

Inconel 718 ◽

Shear Plane ◽

Material Model ◽

Constitutive Law ◽

Percentage Error ◽

Force Model ◽

Inconel 718 Alloy ◽

Average Percentage ◽

Constitutive Material Model

This article presents a cutting force model for the milling of Inconel 718 whose machinability is considered to be very poor. The Johnson–Cook constitutive material model is used to determine the flow stress of Inconel 718 while the shear angle is determined based on a shear plane model assuming that the total energy on the shear plane plus the energy on the rake face is minimum. The temperature in the machining region is determined by using an iterative process. Finally, the cutting forces on each tooth of the milling cutter are calculated from its chip load considering the oblique cutting effects. The model is then verified by comparing the model predictions with the experimental data under the corresponding conditions, which shows a relatively good agreement with an average percentage error of 10.5% along the feed and normal directions.

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Finite element simulation of machining Inconel 718 alloy including microstructure changes

International Journal of Mechanical Sciences ◽

10.1016/j.ijmecsci.2014.08.007 ◽

2014 ◽

Vol 88 ◽

pp. 110-121 ◽

Cited By ~ 83

Author(s):

F. Jafarian ◽

M. Imaz Ciaran ◽

D. Umbrello ◽

P.J. Arrazola ◽

L. Filice ◽

...

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Inconel 718 ◽

Inconel 718 Alloy ◽

Microstructure Changes ◽

Element Simulation

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Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining

10.1115/imece1999-0689 ◽

1999 ◽

Author(s):

Roy J. Schimmel ◽

William J. Endres ◽

Robin Stevenson

Keyword(s):

Metal Cutting ◽

Material Model ◽

Material Response ◽

The Past ◽

Edge Geometry ◽

Orthogonal Machining ◽

Tool Edge ◽

Measured Force ◽

Data Yield ◽

Force Data

Abstract It is well known that the edge geometry of a cutting tool affects the forces measured in metal cutting. Two experimental methods have been suggested in the past to extract the ploughing (non-cutting) component from the (total) measured force; 1) the extrapolation approach and 2) the dwell force technique. This study reports the behavior of zinc during orthogonal machining, using tools of controlled edge radius. It was determined that application of neither the extrapolation nor dwell approaches yielded a material response that is consistent with the known behavior of zinc. Further analysis shows that the edge geometry modifies the shear zone of the material and thereby modifies the forces. When analyzed this way, the measured force data yield the expected material response without requiring recourse to an additional ploughing component.

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Effects of the Flow Stress in Finite Element Simulation of Machining Inconel 718 Alloy

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.611-612.1210 ◽

2014 ◽

Vol 611-612 ◽

pp. 1210-1216 ◽

Cited By ~ 4

Author(s):

Farshid Jafarian ◽

Mikel Imaz Ciaran ◽

Pedro José Arrazola ◽

Luigino Filice ◽

Domenico Umbrello ◽

...

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Inconel 718 ◽

Orthogonal Cutting ◽

Material Model ◽

Material Behavior ◽

Machining Process ◽

Inconel 718 Alloy ◽

Element Simulation ◽

Inconel 718 Superalloy

Inconel 718 superalloy is one of the difficult-to-machine materials which is employed widely in aerospace industries because of its superior properties such as heat-resistance, high melting temperature, and maintenance of strength and hardness at high temperatures. Material behavior of the Inconel 718 is an important challenge during finite element simulation of the machining process because of the mentioned properties. In this regard, various constants for Johnson–Cook’s constitutive equation have been reported in the literature. Owing to the fact that simulation of machining process is very sensitive to the material model, in this study the effect of different flow stresses were investigated on outputs of the orthogonal cutting process of Inconel 718 alloy. For each model, the predicted results of cutting forces, chip geometry and temperature were compared with experimental results of the previous work at the different feed rates. After comparing the results of the different models, the most suitable Johnson–Cook’s material model was indentified. Obtained results showed that the selected material model can be used reliably for machining simulation of Inconel 718 superalloy.

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Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1448334 ◽

2002 ◽

Vol 124 (3) ◽

pp. 536-543 ◽

Cited By ~ 33

Author(s):

Roy J. Schimmel ◽

William J. Endres ◽

Robin Stevenson

Keyword(s):

Metal Cutting ◽

Material Model ◽

Material Response ◽

The Past ◽

Edge Geometry ◽

Orthogonal Machining ◽

Tool Edge ◽

Measured Force ◽

Data Yield ◽

Force Data

It is well known that the edge geometry of a cutting tool affects the forces measured in metal cutting. Two experimental methods have been suggested in the past to extract the ploughing (noncutting) component from the total measured force: (1) the extrapolation approach and (2) the dwell force technique. This study reports the behavior of zinc during orthogonal machining using tools of controlled edge radius. Application of both the extrapolation and dwell approaches showed that neither produces an analysis that yields a material response consistent with the known behavior of zinc. Further analysis shows that the edge geometry modifies the shear zone of the material and thereby modifies the forces. When analyzed this way, the measured force data yield the expected material response without requiring recourse to an additional ploughing component.

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Measuring the effect of residual stress on the machined subsurface of Inconel 718 by nanoindentation

PLoS ONE ◽

10.1371/journal.pone.0245391 ◽

2021 ◽

Vol 16 (1) ◽

pp. e0245391

Author(s):

Ling Chen ◽

Qirui Du ◽

Miao Yu ◽

Xin Guo ◽

Wu Zhao

Keyword(s):

Mechanical Properties ◽

Residual Stress ◽

Inconel 718 ◽

Material Model ◽

Hardened Layer ◽

Gradient Material ◽

Material Surface ◽

Inconel 718 Alloy ◽

Finite Element Software ◽

Stress States

Inconel 718 alloy is widely used in aero-engines and high-temperature environments. However, residual stress caused by processing and molding leads to an uneven distribution of internal pressure, which reduces the reliability of service process. Therefore, numerical simulation of the nanoindentation process was applied to evaluate the effect of residual stress on the machined subsurface of Inconel 718. A gradient material model of Inconel 718 was established in ABAQUS finite element software. Mechanical properties based on nanoindentation testing showed an influence of residual stress in combination with indenter geometry. The orthogonal experimental results show that under diverse residual stress states, the indenter’s geometry can affect the pile-up of the material surface after nanoindentation and significantly influence the test results. With increases in piling-up, the error caused by residual stress on the characterization of the mechanical properties of the hardened layer increases. Through the establishment of a numerical model, the influence of residual stress can be predicted within nanoindentation depths of 300 nm.

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