A cutting forces model for milling Inconel 718 alloy based on a material constitutive law

2012 ◽  
Vol 227 (8) ◽  
pp. 1761-1775 ◽  
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.

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

2014 ◽  
Vol 611-612 ◽  
pp. 1210-1216 ◽  
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.

Finite Element Simulation of the Cutting Process for Inconel 718 Alloy Using a New Material Constitutive Model

2016 ◽  
Vol 693 ◽  
pp. 1046-1053
Author(s):  
Xiang Yu Wang ◽  
Chuan Zhen Huang ◽  
Jun Wang ◽  
Bin Zou ◽  
Guo Liang Liu ◽  
...  
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Finite Element Simulation ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Process ◽  
Inconel 718 Alloy ◽  
Cutting Edge Radius ◽  
Material Constitutive Model ◽  
Element Simulation

Inconel 718 alloy is a typical difficult-to-cut material and widely used in the aerospace industry. Finite element simulation is an efficient method to investigate the cutting process, whereby a work material constitutive model plays an important role. In this paper, finite element simulation of the cutting process for Inconel 718 alloy using a new material constitutive model for high strain rates is presented. The effect of tool cutting edge radius on the cutting forces and temperature is then investigated with a view to facilitate cutting tool design. It is found that as the cutting edge radius increases, the characteristics of tool-work friction and the material removal mechanisms change, resulting in variation in cutting forces and temperature. It is shown that a smaller cutting edge radius is preferred to reduce the cutting forces and cutting temperature.

Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination

2013 ◽  
Vol 7 (1) ◽  
pp. 30-38 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Motohiro Shimada ◽  
Kazunari Teramoto ◽  
Eiji Usui ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Direction ◽  
Three Dimensional ◽  
Shear Plane ◽  
Cutting Parameters ◽  
Force Model ◽  
Chip Flow ◽  
Inclination Angles ◽  
Cutting Model

A force model for milling with cutter axis inclination is presented. The model predicts the cutting force and chip flow direction. Three-dimensional chip flow is interpreted as a piling up of the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities in the inclined coordinate system with a ball end mill. The chip flow direction is determined to minimize the cutting energy consumed into the shear energy on the shear plane and the friction energy on the rake face. Then, the cutting force is predicted in the chip flow determined model. The presented cutting model is verified by comparing the predicted cutting forces to the measured forces in the actual cutting tests. As an advantage of the presented force model, the change in the chip flow direction during one rotation of the cutter is also predicted in the simulation for the cutter axis inclination and the cutting parameters. In the simulation, the effect of cutter axis inclination on the cutting process is discussed in terms of the tool wear and surface finish. The cutting force charts, in which the maximum values of the positive and the negative cutting forces are simulated for the inclination angles, are presented to review the cutter axis inclination. The applicable cutter axis inclination can be determined by taking into account the thresholds of the cutting force components.

Mechanistic Based Cutting Force Model During Ultrasonic Assisted Turning with Self-Lubricating Cutting Inserts

2019 ◽  
Vol 18 (01) ◽  
pp. 133-155 ◽  
Author(s):  
Varun Sharma ◽  
Pulak M. Pandey
Keyword(s):  
Cutting Forces ◽  
Mechanistic Model ◽  
Percentage Error ◽  
Force Model ◽  
Average Force ◽  
Free Body Diagram ◽  
Ultrasonic Assisted ◽  
Cutting Insert ◽  
Cutting Inserts ◽  
On Chip

The present research paper presents a mechanistic model for determining the cutting forces during Ultrasonic Assisted Turning (UAT) process using self-lubricating textured cutting inserts. In order to understand the mechanics of the process, forces on chip have been analyzed by using free body diagram. The force and momentum equilibrium on chip have been used to define the governing force equations. The effect of ultrasonic vibrations has been considered by taking the average force of cutting over a complete cycle of vibration. The self-lubricating cutting insert has been modeled to study the effect of intermittent cutting and thin lubricating layer formation at tool-chip interface. The validation of the developed model has been done by performing UAT experiments with self-lubricating textured cutting inserts. It is observed that percentage error of prediction by mechanistic model in determining main and radial components of cutting forces is of the order of 6.73% and 14.67%, respectively with respect to the experimental values.

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

PLoS ONE ◽  
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.

Cutting Force Model for Heat Assisted Titanium Alloy Milling

2014 ◽  
Vol 887-888 ◽  
pp. 1191-1194 ◽  
Author(s):  
Chang Yi Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Shear Banding ◽  
Cutting Speed ◽  
Constitutive Law ◽  
Force Model ◽  
Machining Processes ◽  
Machine Material ◽  
The Impact

Thermal energy sources have been applied for softening the difficult-to-machine material when it is combined with conventional machining processes. Cutting forces has been reduced during the process. To investigate the plastic deformation property of workpiece materials heated by thermal sources, and its influence to the cutting forces, the analytical model of orthogonal cutting is established. The impact of cutting speed and initial temperature of the shear banding to the cutting forces are taken account of, based on adiabatic shear banding model and Johnson-Cook material constitutive law. The shear banding average shear stress failure criteria has been proposed to decide the fracture between workpiece and chip. Simulation has been carried out and compared with experimental data of laser-heat assisted titanium alloy milling, showing good agreement.

scholarly journals Effect of Pre-Stress on Laser-Induced Thermoplastic Deformation of Inconel 718 Beams

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 1847
Author(s):  
Jacek Widłaszewski ◽  
Zdzisław Nowak ◽  
Piotr Kurp
Keyword(s):  
Mechanical Loading ◽  
Inconel 718 ◽  
Laser Heating ◽  
Local Heating ◽  
Quantitative Description ◽  
Bending Moment ◽  
Material Model ◽  
Hybrid Techniques ◽  
Constitutive Material Model ◽  
External Forces

Laser thermal forming is an application of laser heating without any intentional use of external forces. Force-assisted laser bending and laser-assisted bending are hybrid techniques, which combine the use of external forces and local heating to increase the effectiveness of forming. A quantitative description of bending deformation induced by concurrent laser heating and mechanical loading is proposed in this study. Mechanical loading is expressed by the bending moment while the curvature is used to describe the resulting deformation. The contribution of a relatively less known mechanism of laser thermal bending in the hybrid process is identified. The mechanism is able to produce the so-called convex deformation, i.e., bending away from the incident laser beam. Experimental and numerical analysis is performed with thin-walled beams made of Inconel 718 nickel-based superalloy in the factory-annealed state. The Johnson–Cook constitutive material model is used in numerical simulations validated by experimental results.

scholarly journals Cutting Forces Modeling in Finish Turning of Inconel 718 Alloy with Round Inserts

2011 ◽  
Vol 223 ◽  
pp. 75-84 ◽  
Author(s):  
Sebastien Campocasso ◽  
Jean Philippe Costes ◽  
Gérard Poulachon ◽  
Alexis Perez Duarte
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
Orthogonal Design ◽  
Generic Model ◽  
Inconel 718 Alloy ◽  
Cutting Coefficients ◽  
Homogeneous Matrix ◽  
Applied Forces ◽  
Experimental Values ◽  
Clearance Face

In turning, the applied forces have to be known as accurately as possible, especially in the case of difficult-to-cut materials for aircraft workpieces finishing operations. Traditionally, edge discretisation methodology based on local cutting laws is used to determine the cutting forces and results are usually considered suitable. Nevertheless, only the rake face is considered in most of studies and the cutting relations are determined by direct identification with a straight edge. This study deals with finishing operations of Inconel 718 alloy with one type of round insert. The main objective is to formulate a novel cutting forces model, taking into account the clearance face. First, a generic model based on a geometrical description using homogeneous matrix transformation is presented. Then, cutting coefficients are identified by inverse identification from experimental measurements distributed with an orthogonal design experiment including tool wear. Finally, modeling and experimental values of the cutting forces are compared and the identified model is analysed.

Force Prediction in Milling of Titanium Alloy

2012 ◽  
Author(s):  
Takashi Matsumura ◽  
Shouichi Tamura
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Flow Direction ◽  
Orientation Angle ◽  
Shear Plane ◽  
Cutting Parameters ◽  
Material Model ◽  
Force Model ◽  
Alloy Plate ◽  
Chip Flow

Titanium alloy plate formed in rolling has anisotropic properties. The effect of anisotropy on cutting force should be considered in determination of the cutting parameters. A force model of anisotropic materials is presented to predict the cutting forces in milling. In the force model, three-dimensional chip flow is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities, where the chip flow direction is determined to minimize the cutting energy. In the anisotropic material model, the shear stress on the shear plane is defined as a function of the orientation angle of the cutting edge in milling. Therefore, the cutting force depends on the feed direction of the end mill. The force model for milling of Ti-6Al-4V is verified in comparison between the simulated and the measurement.

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