Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations.

Huachen Peng,Yan Xing,Wencheng Tang,Xin Zhou

doi:10.3390/ma14143937

Huachen Peng, Yan Xing + Show 2 more

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https://doi.org/10.3390/ma14143937

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Abstract

The surface residual stress after machining, especially for finishing, has a vital influence on the shape stability and fatigue life of components. The current study focuses on proposing an original empirical equation to predict turned surface residual stress for Inconel 718 material, taking tool parameters into consideration. The tool cutting-edge angle, rake angle, and inclination angle are introduced for the first time in the equation based on the Inconel 718 material turning experiments and finite element simulations. In this study, the reliability of simulation parameters’ setting is firstly calibrated by comparing the residual stresses and chips of the experiments and simulations. The changing trends of turned forces, temperatures of lathe tool nose, and surface residual stress with turning parameters are analyzed. Then, the predictive equation of surface residual stress is proposed considering relationships between the back-rake angle, the side-rake angle, and the tool cutting-edge angle, rake angle, and inclination angle. Moreover, the genetic algorithm optimizes the objective function to obtain the undetermined coefficients in the prediction equation. Finally, the predicted accuracy of the surface residual stress is proven by comparing the experimental, simulation, and prediction values. The results indicate that the predictive equation of surface residual stress has a good accuracy in predicting turned surface residual stress for Inconel 718 materials. The correlation coefficient, R, and absolute average error between the predicted and the simulated value are 0.9624 and 13.40%, respectively. In the range of cutting parameters studied and experimental errors, this study provides an accurate predictive equation of turned surface residual stress for Inconel 718 materials.

Highlights

Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations
The turned surface residual stress for Inconel 718 material was studied in the present work
The novel surface residual stress prediction equation was proposed on the basis of cutting force, cutting temperature, feed, depth of cut, and cutting speed in the turning process

Summary

Introduction

Nickel-based superalloys are widely applied in the aviation industry, such as in the manufacture of aeroengines, because they have excellent mechanical performance under high temperature and pressure. Pr , Ps , and Po , are perpendicular to each other and intersect at a point on the cutting edge. Vf is the axis of feed motion and vc is the axis of cutting motion. In this way, the rake angle γ0 (the O–O view), the tool cutting-edge angle κr (the top view), and the inclination angle λs (S-direction view) are determined

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