scholarly journals Drilling Force Characterization during Inconel 718 Drilling: A Comparative Study between Numerical and Analytical Approaches

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4820
Author(s):  
Salman Pervaiz ◽  
Wael A. Samad
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Power Plants ◽  
Mechanistic Model ◽  
Rate Sensitivity ◽  
Drilling Force ◽  
Workpiece Material ◽  
Pilot Hole ◽  
Analytical Approaches

In drilling operations, cutting forces are one of the major machinability indicators that contribute significantly towards the deviations in workpiece form and surface tolerances. The ability to predict and model forces in such operations is also essential as the cutting forces play a key role in the induced vibrations and wear on the cutting tool. More specifically, Inconel 718—a nickel-based super alloy that is primarily used in the construction of jet engine turbines, nuclear reactors, submarines and steam power plants—is the workpiece material used in the work presented here. In this study, both mechanistic and finite element models were developed. The finite element model uses the power law that has the ability to incorporate strain hardening, strain rate sensitivity as well as thermal softening phenomena in the workpiece materials. The model was validated by comparing it against an analytical mechanistic model that considers the three drilling stages associated with the drilling operation on a workpiece containing a pilot hole. Both analytical and FE models were compared and the results were found to be in good agreement at different cutting speeds and feed rates. Comparing the average forces of stage II and stage III of the two approaches revealed a discrepancy of 11% and 7% at most. This study can be utilized in various virtual drilling scenarios to investigate the influence of different process and geometric parameters.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

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.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

Simulations of Milling Process of Inconel 718 Alloy Based on Three Dimensional Finite Element Models

2014 ◽  
Vol 1017 ◽  
pp. 399-405 ◽  
Author(s):  
Lin Jiang He ◽  
Hong Hua Su ◽  
Jiu Hua Xu ◽  
Jia Bao Fu
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Metal Removal ◽  
Cutting Temperature ◽  
Milling Process ◽  
Material Behavior ◽  
Tool Geometry ◽  
Mass Scaling ◽  
Element Removal

Nickel-based alloy is known as one of the most difficult–to-machine materials and the milling process is one of the most common metal removal operations. Modeling and simulation of milling process have the potential for understanding the milling mechanism, improving cutting tool designs and selecting optimum conditions, especially in advanced applications such as high-speed milling. This paper presents a 3D coupled thermo-mechanical finite element model based on ABAQUS\Explicit for the simulation of Inconel 718 chip formation in metal cutting. In the simulations, a Lagrangian formulation with an explicit solution scheme and a penalty contact algorithm has been used. The material behavior is modeled with classical Johnson-cook plasticity constitutive model and dynamic failure criteria for element removal, coupled with adaptive meshing and mass scaling technology for limiting the calculation time. The milling tool is modeled in UG software according to the real tool geometry, and meshed as a rigid tool. In order to verify the accuracy of 3D simulation, results (cutting forces and cutting temperature) were compared with the experimental results under the same cutting conditions as the simulations. The results obtained indicate that the simulation methodology is capable of predicting the cutting forces and cutting temperature. It suggests that 3D finite element simulation model of cutting processes can be truly trusted.

Numerical Modeling the Effect of Tool-Chip Friction in Orthogonal Cutting AISI4340

2010 ◽  
Vol 29-32 ◽  
pp. 1815-1819 ◽  
Author(s):  
Gang Tao Xu ◽  
Yu Sheng Li
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Clear Understanding ◽  
Workpiece Material ◽  
Explicit Finite Element ◽  
Plastic Model

A thermo-elastic-plastic model using explicit finite element code ABAQUS 6.8 was developed to investigate the effect of tool-chip friction in orthogonal cutting AISI4340. A.L.E finite element model was presented and the Johnson-Cook plastic model was used to model the workpiece material which is suitable for modeling cases with high strain, strain rate, strain hardening, and non-linear properties. In this paper, three different friction coefficient values of 0.2, 0.3, 0.4 were considered to study the effect on Cutting temperature, cutting forces and cutting stress. The results told a clear understanding of the effect of friction coefficient in orthogonal metal cutting, and larger friction coefficient induced higher cutting temperature, bigger cutting forces and larger cutting stress.

A Comparison of Failure Load Assessment Methods for Thin-Walled Tubes With Cracks

2009 ◽  
Author(s):  
Hyun Su Kim ◽  
Chang Kyun Oh ◽  
Tae Eun Jin
Keyword(s):  
Finite Element ◽  
Test Data ◽  
Heat Exchangers ◽  
Power Plants ◽  
Failure Modes ◽  
Estimation Method ◽  
Operational Experience ◽  
Failure Loads ◽  
Thin Walled ◽  
Analytical Approaches

Heat exchangers in fossil and nuclear power plants comprise thousands of thin-walled tubes. Operational experience shows that cracks have been frequently detected in the tubes. Since the structural integrity of the heat exchangers is crucial from the viewpoint of safety and reliability, the integrity evaluation of the cracked tubes is quite important. The failure modes of the cracked tubes are determined herein in accordance with Section XI of ASME Code. In addition, failure loads are evaluated using various methods and compared with test data in order to determine an optimum estimation method. The analysis results show that the failure mode of the cracked tubes is plastic collapse. Also, the predicted failure loads by finite element limit analyses agree very well with the corresponding test data, whereas the analytical approaches are significantly under predictive depending on the crack type and size. It is, therefore, considered that the finite element limit load approach can be applied to the practical integrity evaluation and the establishment of an optimum inspection strategy for managing the heat exchanger tubes.

The Simulation of Cutting Force and Temperature Field in Turning of Inconel 718

2010 ◽  
Vol 458 ◽  
pp. 149-154 ◽  
Author(s):  
Zhen Chao Yang ◽  
Ding Hua Zhang ◽  
Xin Chun Huang ◽  
Chang Feng Yao ◽  
Yong Shou Liang ◽  
...  
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Cutting Force ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Maximum Temperature ◽  
Cutting Depth ◽  
Finite Element Software

Finite element method (FEM) is a powerful tool to predict cutting process variables such as temperature field which are difficult to be obtained from experimental methods. The turning process of Inconel 718 is simulated by AdvantEdge which is professional metal-cutting processing finite element software. The effects of cutting speed, feed and cutting depth on cutting force and temperature field are analyzed. The results show that cutting forces decrease with cutting speed increasing, and increase with feed and cutting depth, and the influence of cutting depth on cutting forces is significant. The maximum temperature in the cutting zone located on the rake face at a distance of about 0.01 mm from the tool tip. As cutting speed and feed increase, the maximum temperature in the cutting area increases. The influence of cutting speed on cutting temperature is significant, but the cutting depth has little impact on temperature.

Mechanistic Model for Dynamic Forces in Micro-Drilling

2001 ◽  
Author(s):  
Yongping Gong ◽  
Kornel F. Ehmann
Keyword(s):  
Cutting Forces ◽  
Mechanistic Model ◽  
Chip Thickness ◽  
Radial Force ◽  
Drilling Force ◽  
Cross Sectional ◽  
Workpiece Surface ◽  
Chip Area ◽  
Dynamic Forces ◽  
Micro Drilling

Abstract By considering the effects of drill grinding errors and drill deflections, dynamic cutting chip thickness models were developed which in combination with workpiece surface inclination effects allowed the formulation of expressions for the dynamic cutting chip cross-sectional area. By using the dynamic chip thickness and dynamic cutting chip area to replace their static counterparts, static drilling force models were extended to facilitate the prediction of dynamic cutting forces in micro-drilling processes. The geometric characteristics of micro-drills were considered in these mechanistic force models. Separate thrust, torque and radial force models for the major cutting edges, secondary cutting edge and for the indentation zone were developed. The effects of drill installation errors on the radial cutting forces acting on the chisel edge and the major cutting edges were also included.

Finite Element Method and Experimental Investigation of Hot Turning of Inconel 718

2016 ◽  
Vol 16 ◽  
pp. 24-32 ◽  
Author(s):  
A.K. Parida ◽  
K.P. Maity
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Chip Surface ◽  
Hot Turning

In the present work, a finite element modeling of hot turning has been carried out for predicting computationally the state variables like temperature distribution on chip surface and cutting forces in hot machining of Inconel 718. The hot turning operation has been carried out with L9 orthogonal design of experiment (DOE) with varying cutting speed, feed rate, heating temperature and constant depth of cut to analyze the responses. The model predicts the temperature distribution, cutting forces with and without heating. DEFORM 2D is applied for modeling hot turning simulation as similar as possible to the experimental result. Flow stress and input parameters should be modeled according to the actual machining conditions. The predicting results i.e. cutting forces and temperature distribution were partially validated with the experimental data.

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