Minimization of Surface Roughness and Residual Stress in Grinding Operations of Inconel 718

Abstract

The residual stress and surface roughness enhancement of ground surfaces can decrease the lifetime of workpiece by reducing its fatigue life. It is critical to accurately predict and minimize the residual stress and surface toughness of ground surfaces in order to enhance efficiency of part production using grinding operations. A virtual machining system is developed in the research work to minimize the surface integrity and residual stress during grinding operations of Inconel 718. The cutting temperature during grinding operations is calculated using the Inconel alloy Johnson–Cook law models. Then, using the finite element method, residual stress during the grinding operation is estimated. Utilizing the established virtual machining method, the surface roughness is predicted in the study. Using the Taguchi optimization approach, the grinding parameters of depth of cut and feed velocity are optimized in order to reduce surface roughness as well as residual stress throughout grinding operations on Inconel 718 superalloy. To confirm the effectiveness of the developed technique in the study, simulation and experimentation are conducted. As a result, the quality as well as reliability of the ground surfaces can be enhanced by using the developed virtual machining system in the study to minimize the surface roughness and residual stress of produced parts using grinding operations.