2d finite element analysis of inconel 718 under turning processes

Abstract

Nickel-based alloys like INCONEL 718 are extensively used in manufacturing aero-engine components due to their excellent mechanical and chemical properties at high elevated operating temperatures. The machining of these alloys often poses a challenge due to its rapid changes in machining parameters such as microstructure of the material, hardness and surface behavior due to high plastic deformation during machining. Also, thermal properties such as low thermal conductivity contribute to high temperatures in the cutting zone. This paper aims to create a numerical model to examine the cutting forces induced by orthogonal machining. The FE method was used to simulate and analyze the cutting tool temperature and cutting forces. In this work, the Finite element model has been developed using ABAQUS to model 2D-orthogonal cutting of the INCONEL 718 using the WC tool coated with TiN. The cutting forces and tool temperatures were predicted using Johnson-Cook formulation under different conditions like dry and cryogenic conditions. For the cryogenic model, all types of heat transfer coefficients were considered. A dynamic explicit time integration technique with arbitrary lagrangian eulerian (ALE) adaptive meshing technique was employed to simulate the model. The simulations are conducted at speeds 1000 mm/sec, 1250 mm/sec, 1500 mm/sec, it feeds 0.08 mm/rev, 0.1 mm/rev, 0.15 mm/rev, and depth of cut of 0.5 mm, 0.75 mm, 1 mm. For the given tool–work combination it is found that at speed 1250 mm/sec, feed rate 0.08 mm/rev, depth of cut 0.75 mm the cutting force results are good.