The Cutting Simulation of Inconel 718

2010 ◽  
Vol 43 ◽  
pp. 717-721 ◽  
Author(s):  
Jia Long Ren ◽  
Qing Yu Zheng ◽  
Ren He ◽  
Chun Yan Zhang
Keyword(s):  
Heat Transfer ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Optimal Combination ◽  
Cutting Depth ◽  
Nickel Based Superalloy ◽  
Friction Factors ◽  
3D Software ◽  
Cooling And Lubrication ◽  
Deform 3D

The chemical composition and properties of nickel-based superalloy Inconel 718 was investigated first. Turning Inconel 718 was simulated by Deform-3D software to figure out main affection factors, and optimal combination of cutting speed, feed rate and cutting depth was introduced. In addition, different cooling and Lubrication methods (heat transfer coefficient f of cooling and tool-chip friction factors) for cutting of Inconel 718 was studied, and a best cooling/lub mode was obtained.

The Research on Milling Force in High-Speed Milling Nickel-Based Superalloy of Inconel 718

2013 ◽  
Vol 395-396 ◽  
pp. 1031-1034
Author(s):  
Can Zhao ◽  
Yu Bo Liu
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Cutting Speeds

This paper makes an experiment in high-speed milling of Inconel 718. Cutting tests were performed using round and ceramic tools, at feeds from 0.06 to 0.14 mm/tooth, Axial Depth of Cut from0.5 to 1.5mm,and cutting speeds ranging from 500 to 1037 m/min. The behaviour of the cutting forces during machining was then measure. The results show that cutting force increases first and then decreases with the increase of feed per tooth, the tool chipping and groove wear were found with the increase of axial cutting depth, and cutting force is increased; the increase in cutting force with the cutting speed increases, when the cutting speed reaches a critical speed, the cutting force as the cutting speed increases began to decline.

scholarly journals Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

2018 ◽  
Vol 2 (3) ◽  
pp. 50 ◽  
Author(s):  
Hussien Hegab ◽  
Hossam Kishawy
Keyword(s):  
Inconel 718 ◽  
Government Regulation ◽  
Effective Properties ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Al2o3 Nanoparticles ◽  
Machining Performance ◽  
Multi Wall Carbon Nanotubes ◽  
Minimum Quantity ◽  
Cooling And Lubrication

Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al2O3 nanoparticles.

scholarly journals A Special Extrusion-shear Manufacturing Method for Magnesium Alloy Rods Based on Finite Element Numerical Simulation and Experimental Verification

2022 ◽  
Author(s):  
Ou Zhang ◽  
Hongjun Hu ◽  
Huiling Zhang ◽  
Hui Zhao ◽  
Ding-fei Zhang ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Metal Flow ◽  
Temperature Fields ◽  
Extrusion Speed ◽  
Manufacturing Method ◽  
Grain Sizes ◽  
Friction Factors ◽  
Finite Element Numerical Simulation ◽  
3D Software ◽  
Deform 3D

Abstract To research the influences of process parameters on a special extrusion-shearmanufacture method for magnesium alloy rods, deform-3d software with finite elementsimulations has been used to analyze the material flows of deformed magnesium alloysAZ31B during the extrusion-shear (ES) process, as well as the grain sizes anddistribution of extrusion loads, stresses and strains, and blank temperatures. Temperaturefields, stress fields, strain fields and temperature fields varying with different blankpreheating temperatures, extrusion speed and extrusion ratios were simulated. Influences ofdifferent extrusion conditions and different die structures on microstructures of rods prepared by ES process has been researched. Extrusion forces decrease with the increasing extrusion temperatures, decreasing extrusion ratios, increasing die channel angles and decreasing friction coefficients. The flow velocities of metal in the ES die increase with development of ES process. Increasing the channel angles and reducing the friction factors would increase the outflow velocities of metal, but it has little effect on the uniformity of metal flow. The increase in friction and extrusion speed would increase the temperatures of the ES die. The ES process can prepare finer and more uniform microstructures than those prepared by direct extrusion under the same conditions.

Study on Wear Mechanism of Carbide Tool in Machining Inconel 718

2013 ◽  
Vol 589-590 ◽  
pp. 323-326 ◽  
Author(s):  
Yi Hang Fan ◽  
Liang Zhou ◽  
Shuang Zhu Song ◽  
Feng Lian Sun
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Wear Debris ◽  
Oxidation Reaction ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Tool Breakage ◽  
Nickel Based Superalloy ◽  
Cemented Carbide Tools

Tool wear is a problem in machining nickel-based superalloy Inconel 718, and it is thus of great importance to understand and quantitatively predict tool wear. The experiments of machining Inconel 718 with cemented carbide tools (uncoated and coated) were carried out. Some new observations and analysis of tool wear through CCD, SEM and EDS were done. The results showed that at low cutting speed, the built up edge (BUE) formed easily and dropped at last which caused severe cutting tool breakage. When cutting speed came to 30m/min, the main reason that caused cutting tool wear was that the tool material fell off from the tool body at the form of wear debris. What’s more, the element diffusion between tool and workpiece and oxidation reaction all accelerate the formation and the cast of the wear debris.

Finite Element Simulation of Nickel-Based Alloy Cutting Process Based on DEFORM- 3D

2011 ◽  
Vol 175 ◽  
pp. 352-356 ◽  
Author(s):  
Jia Long Ren ◽  
Chun Yan Zhang ◽  
De Peng Yuan
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Average Temperature ◽  
Deform 3D

To analysis cutting mechanism and heat transfer coefficient of Ni-based superalloy IN718, this paper introduced a three-dimensional finite element model for cutting process based on DEFORM-3D V6.1, and cutting force Fy and cutting temperature T under different feed rate f , cutting speed v and back engagement ap were obtained. The temperature variation during cutting process under different cooling method was analyzed. The simulation results indicate that the influence of back engagement ap on the cutting force Fy is the greatest, while that of cutting speed v is minor; and for cutting temperature T, influence of cutting speed v is the greatest, while that of back engagement ap is minor. Influence of heat transfer coefficient on highest temperature and average cutting force Fy is minor, but its influence on average temperature is quite obvious. Greater heat transfer coefficient is less average temperature.

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.

Failure Mechanisms of Carbide Tool in High Speed Milling of Inconel 718

2010 ◽  
Vol 97-101 ◽  
pp. 1920-1924 ◽  
Author(s):  
Xin Yu Song ◽  
Jun Zhao
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
High Hardness ◽  
High Wear Resistance ◽  
Thermal Crack ◽  
Cutting Depth ◽  
Nickel Based Superalloy ◽  
Diffusion Wear ◽  
Coating Delamination ◽  
Coated Carbide

TiAlN/TiN multilayer PVD coated carbide is one of the dominant tool materials for the milling applications of Inconel 718 due to its high hardness, high wear resistance, and high thermal stability. In this paper a study was undertaken to investigate the wear of TiAlN/TiN multilayer PVD-coated carbide tools during milling of nickel-based superalloy Inconel 718 at high speeds. The wear patterns and wear mechanisms were analyzed. Results show that the dominant wear patterns were coating delamination, thermal crack, micro-chipping，chatter marks and breakage. When the cutting depth was 1mm, the coated tool was predominantly subjected to adhesion and diffusion wear throughout the duration of cutting. Adhesive wear on one hand accelerated the extension of thermal crack, on the other hand promoted the diffusion wear. When the cutting depth was 3mm, the tool life was determined by chatter which could lead to failure of the cutting tool in very short time.

Numerical Simulation for Heat Transfer Process of Clinching with Magnesium Alloys

2012 ◽  
Vol 472-475 ◽  
pp. 1995-1999 ◽  
Author(s):  
Shan Ling Han ◽  
Yi Wei Wu ◽  
Qing Liang Zeng
Keyword(s):  
Heat Transfer ◽  
Magnesium Alloys ◽  
Transfer Process ◽  
Room Temperature ◽  
Heating Time ◽  
Heat Transfer Process ◽  
High Efficient ◽  
3D Software ◽  
Joining Process ◽  
Deform 3D

The clinching process of magnesium alloys has a great potential of being high efficient joining method, but it is restricted by the limited formability of magnesium alloys at room temperature. To form acceptable joints without cracking, it is usually required to heat the parts to about 220°C. However, the pre-heating times of traditional forming method is more than 3 to 6 seconds, the application of clinching for magnesium alloys is restricted by the over long periods of heating time. A new joining process with a contoured die is introduced to offer great benefits, especially in pre-heating time. Then the heat transfer process is simulated with DEFORM-3D software. The results show that the pre-heating time reduced to less than 1 second. Thus it is efficient and reliable in joining of magnesium alloys parts.

Laser Assisted Finish Turning of Inconel 718: Process Optimization

2009 ◽  
Author(s):  
Salar Tavakoli ◽  
Helmi Attia ◽  
Raul Vargas ◽  
Vincent Thomson
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Tool Material ◽  
Significant Drop ◽  
Nickel Based Superalloy ◽  
Wide Range ◽  
Coated Carbide ◽  
Conventional Machining

Generally, superalloys have superior strength and toughness compared to conventional engineering material. However, while applications for such materials are growing, the improvement of their machinability has not been improved in parallel. Of particular interest to the aerospace industry, are nickel-based superalloys. Inconel 718, which is one type of nickel-based superalloy, is considered difficult-to-machine at room temperature due to the fact that it retains much of its strength at high temperatures. Conventional machining methods applied to these materials results in excessive tool wear and poor surface finish. One approach, which is becoming increasingly popular with difficult-to-machine materials, is laser assisted machining (LAM). This study assesses the effect of LAM on the machinability of Inconel 718 using a triple-layer coated carbide tool in terms of cutting forces, tool wear and surface finish. A focused Nd:YAG laser beam was used as a localized heat source to thermally soften the workpiece prior to material removal. Finishing operations were assumed throughout the experiments. Cutting tests were performed over a wide range of cutting speeds (ranging from 100 to 500 m/min) and feeds (ranging from 0.125 to 0.500 mm/rev) to determine the optimum cutting speed and feed for each tool material. Results showed a significant drop in all three components of cutting force when thermal softening caused by the laser power was in effect. A two to three fold improvement was observed in terms of surface finish and tool wear under LAM conditions when compared to conventional machining.

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