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.

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.

Statistical Analysis of Cutting Forces in Turning Inconel 718 with Coated Carbide Tools

2010 ◽  
Vol 135 ◽  
pp. 96-101 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
Tong Chao Ding ◽  
Yuan Wei Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Regression Equations ◽  
Dry Cutting ◽  
Cutting Force Components ◽  
Optimal Cutting Parameters ◽  
Coated Carbide

The experimental study presented in this paper aims to investigate the effects of cutting parameters on cutting forces, and search the optimal cutting parameters for the minimum cutting forces during turning Inconel 718 under dry cutting conditions. Based on Taguchi method, a L25 (53) array was designed to conduct the turning experiments. The experimental results indicate that the best condition for the minimum cutting force components is the combination of 45m/min cutting speed, 0.08mm/r feed rate, and 0.2mm depth of cut. The effects of the cutting parameters on cutting forces are investigated while employing the analysis of variance (ANOVA). Finally, the quadratic regression equations for cutting forces were formulated, which can well describe the relationship between cutting parameters and cutting forces.

Experimental and Numerical Machining of AA 5083

2011 ◽  
Vol 189-193 ◽  
pp. 4419-4424
Author(s):  
Behnam Davoodi ◽  
Mohammad Bagher Momeni ◽  
Mohammad Reza Eslami
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Simulation Software ◽  
Constitutive Law ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Element Modeling

The experimental machining and finite element modeling of 2D turning of AA5083 is presented. The ABAQUS/Explicit machining simulation software is applied for the finite element modeling. The experimental orthogonal machining for were conducted to investigate the effects of various machining parameters on chip morphology, machined surface condition, and resulting cutting forces. The measured cutting forces was compared to finite element modeling results with good agreement. The effects of cutting speed and rack angle of tool cutting factor for productivity in AA5083 machining, depth of cut, on the peak tool temperature are investigated. 2D Finite Element Model (FEM) of chip formation process, set up with an Arbitrary Lagrangian-Eulerian (ALE) formulation, proposed in the software ABAQUS/Explicit .the thermo-viscoplastic behavior of the workpiece material is modeled by the Johnson-Cook (JC) constitutive law. This study explores the use of experimental and finite element modeling to study the cutting force. Results of this research help to guide the design of new cutting tool materials and coatings and the studies of chip formation to further advance the productivity of AA5083 machining.

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.

scholarly journals Finite element analysis and modeling of temperature distribution in turning of titanium alloys

10.30544/323 ◽  
2018 ◽  
Vol 24 (1) ◽  
pp. 59-69 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Mohan Kumar ◽  
Kumaraesan Shanmugam
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Surface Model ◽  
Element Analysis

The titanium alloys (Ti-6Al-4V) have been widely used in aerospace, and medical applications and the demand is ever-growing due to its outstanding properties. In this paper, the finite element modeling on machinability of Ti-6Al-4V using cubic boron nitride and polycrystalline diamond tool in dry turning environment was investigated. This research was carried out to generate mathematical models at 95% confidence level for cutting force and temperature distribution regarding cutting speed, feed rate and depth of cut. The Box-Behnken design of experiment was used as Response Surface Model to generate combinations of cutting variables for modeling. Then, finite element simulation was performed using AdvantEdge®. The influence of each cutting parameters on the cutting responses was investigated using Analysis of Variance. The analysis shows that depth of cut is the most influential parameter on resultant cutting force whereas feed rate is the most influential parameter on cutting temperature. Also, the effect of the cutting-edge radius was investigated for both tools. This research would help to maximize the tool life and to improve surface finish.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

scholarly journals Microstructure characterisation of Inconel 718 after laser assisted turning

2018 ◽  
Vol 188 ◽  
pp. 02004 ◽  
Author(s):  
Tadeusz Chwalczuk ◽  
Damian Przestacki ◽  
Piotr Szablewski ◽  
Agata Felusiak
Keyword(s):  
Inconel 718 ◽  
Laser Heating ◽  
Dendritic Structure ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Depth Of Cut ◽  
Heat Affect Zone ◽  
Molecular Laser ◽  
Laser Assisted Turning

The paper presents the discussion about the possibility of optimising heating and cutting parameters for turning under laser assisted machining (LAM) conditions. The samples of Inconel 718 after annealing and ageing were used. The laser heating experiments were carried out on the stand equipped with the CO2 molecular laser. Characterisation of samples was performed by an optical microscope, hardness measurements, scanning electron microscopy (SEM) to ensure the exact depth of heat affect zone range and to optimised further cutting parameters. Different absorbing layers for laser beam impact improvement were tested. Turning trials were performed with constant cutting speed vc = 28 m/min and feed f = 0,2 mm/rev. The influence of depth of cut ap on microstructure and its properties were investigated. It was proven that for sequential LAM dendritic structure appears in the laser affected zone of the Ni-based alloy. Such microstructures cause better machinability of Inconel 718 due to surface softening.

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