Abstract
The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient. An equation is presented for the identification of normal mean friction angle of oblique cutting in milling. A simplified oblique cutting model is adopted for obtaining the shear strain and shearing constants for a tool of given helix angle, radial rake angle, and honed edge radius. The shearing and ploughing constants predicted from analytical model using the Merchant’s shear angle formula and the shear flow stress from the selected Johnson–Cook material law are shown to be consistent with the experimental results. The experimentally identified normal friction angles and shearing and edge ploughing constants for the Inconel 718 milling process are demonstrated to have approximately constant values irrespective of the average chip thickness. Moreover, the predicted forces obtained in milling aged Inconel 718 alloy are in good agreement with the experimental force measurements reported in the literature. Without considering the thermal–mechanical coupling effect in the material law, the presented model is demonstrated to work well for milling of both annealed and aged Inconel 718.
Highlights
The milling process is widely used throughout manufacturing industry for the forming and finishing of mechanical parts and components
To facilitate the practical application of oblique cutting mechanics in an industrial setting, the present study presents a dual-mechanism global cutting constant (DGCC) prediction model for the milling of hardto-machine Inconel 718; the proposed model integrates the advantages of mechanistic DGCC models and analytical dual-mechanism variable cutting coefficient (DVCC) models
This paper proposed an integrated dual-mechanism milling constant prediction model for Inconel 718 on the basis of orthogonal and oblique cutting theories, a material constitutive equation, and an explicit consideration of the tool edge ploughing mechanism
Summary
The milling process is widely used throughout manufacturing industry for the forming and finishing of mechanical parts and components. Analytical DVCC models [26,27,29,31] predict shearing and ploughing forces and coefficients without costly experimentation and can be applied to an extensive range of tools with complex micro and macro geometrical structures They require a relatively complex thermomechanical model of oblique cutting along with a suitable work material flow stress model and a rake face normal friction coefficient. The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient and a simplified oblique cutting model.
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