Abstract
Inconel 718 is famous for its applications in the aerospace industry due to its inherent properties of corrosion resistance, wear resistance, high creep strength, and high hot hardness. Despite the favorable properties, it has poor machinability due to low thermal conductivity and high hot hardness. To limit the influence of high cutting temperature in the cutting zone, application of cutting flood is recommended during the cutting operation. Cryogenic cooling is the recommended method when machining Inconel 718. However, there is very limited literature available when it comes to the numerical finite element modeling of the process. This current study is focused on the machinability analysis of Inconel 718 using numerical approach with experimental validations. Dry and cryogenic cooling methods were compared in terms of associated parameters such as chip compression ratio, shear angle, contact length, cutting forces, and energy consumption for the primary and secondary deformation zones. In addition, parameters related to chip morphology were also investigated under both lubrication methods. Chip formation in cryogenic machining was well captured by the finite element assisted model and found in good agreement with the experimental chip morphology. Both experimental and numerical observations revealed comparatively less chip compression ratio in the cryogenic cooling with larger value of shear plane angle. This results in the smaller tool–chip contact length and better comparative lubrication.
Highlights
The group of superalloys formed by combining austenitic nickel and chromium is termed as Inconel
The reduction in the chip compression ratio for cryogenic cutting is linked with comparatively reduced coefficient of friction at the tool chip contact
Both experimental and simulated forces were found slightly lower in cryogenic cutting
Summary
The group of superalloys formed by combining austenitic nickel and chromium is termed as Inconel. Cryogenic cooling termed as one of green solutions for machining Inconel 718 It is evidenced from several sources found in the metal cutting literature that application of cryogenic cooling at the tool–chip cutting interface results in the improvement of hardness and strength of the cutting tool material, reduces. It is observed that at higher cutting speed levels, higher cutting temperature can initiate thermal softening phenomenon for the ductile material; as a result, the workpiece material tends to weld with the cutting tool material resulting a built-up-edge (BUE) This built-up-edge (BUE) can vary the machining performance because this BUE keeps forming and breaking during the machining process. Exposure of low temperature cryogenic coolant can change the hardness, stiffness, and toughness of the cutting tool possibly resulting in the reduction of coefficient of friction (CoF). The simulated data is used to provide a deeper analysis of (i) primary shear deformation zone by calculating the chip compression ratio, shear angle, and contact length; (ii) specific cutting energy (SCE); and (iii) chip morphology such as segmentation, valleys, and peaks for plastic deformation
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