Finite Element analysis: Predicting cutting force in turning of Inconel 625 using ceramic tools

Abstract

Inconel 625 is a unique material due to its characteristic properties of high strength at high temperatures, high corrosion and oxidation resistance. These unique properties thus pose a challenge to machine Inconel 625. Characteristics of work hardening in Inconel 625 generates high cutting force which results in poor surface finish and reduce the performance of cutting tool. Two-dimensional turning operation simulation is considered to evaluate cutting force in this research study. Box- Behnken design of experiment under Response Surface Methodology is used to identify the cutting force with 15 different combinations of cutting speed, feed rate and depth of cut parameters. Predictive mathematical model for cutting force is developed and obtained. From Analysis of Variance (ANOVA), depth of cut had significant influence on cutting force followed by feed rate and cutting speed. Optimization of cutting parameters was carried out and it is recommended that a low combination of depth of cut and feed rate should be selected with a high cutting speed to achieve minimum cutting force. The effect of rake angle on cutting force was investigated for ceramic cutting tools.