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

Abstract

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.