FINITE ELEMENT INVESTIGATION OF MATERIAL MODELS IN

MACHINING SIMULATION OF INCONEL 718

1
Dr.R.Rajappan, 2 D.ANBUSELVAN
1
Prof /HOD&DEAN Department Of Mechanical Engineering, Mailam Engineering College, Mailam
2
M.E Students Final year. Mailam Engineering College, Mailam

ABSTRACT
Inconel 718 is one of the difficult to machine materials and is mainly used for
aerospace applications. Cutting speed in machining of Inconel 718 is limited by shear
localization observed at cutting speed above 61m/min. Adiabatic shear failure is considered
as root cause for chip segmentation. Johnson-Cook material model is used to represent strain,
strain rate and temperature dependence of shear strength of Inconel 718. Cockroft and
Latham’s criterion for catastrophic thermoplastic shear failure is applied to study shear
instability in machining. Commercial finite element (FE) software with 2D explicit code and
Lagrangian formulation is used in finite element simulations. A user subroutine is developed
to incorporate Johnson-Cook material model and Cockroft-Latham’s criterion in the main
code.

In this present work to conduct the finite element simulation in machining of Inconel
718 and observe the chip formation mechanism. To apply the material model to stress, strain
temperature and flow stress in the work material under different machining condition and to
validate the finite element simulations by comparing with the experimental data

iii
1

1.INTRODUCTION
Nickel-based super alloy
development of aerospace began in the
1930s. Need for the more creep resistant
material than the available austenitic
stainless steel propelled research to
develop new superalloy. The principal
characteristics of nickel as an alloy base
are highly phase stability of face centered
cubic(FCC) nickel matrix and
outstanding strength retention up to
0.7Tm (melting point). These
characteristics encourage use of nickel
based superalloys in vast number of
applications subjected high temperatures.
Commercially available nickel base
superalloys include Inconel, Nimonic,
Rene, Udimet, and Pyromet. Inconel 718
is the most frequently used nickel based
superalloys; hence this study is focused
on an investigation into the mechanics of
machining Inconel 718.
1.1 APPLICATIONS OF NICKEL-BASED
SUPERALLOYS
Some of the applications of nickel
based superalloys are in aircraft gas
turbines (e.g. disks, combustion chamber,
casings, shafts, exhaust system, blades,
vanes, burner, cans, stack gas reheaters),
reciprocating engines (e.g. turbochargers,
exhaust valves hot plugs, valve seat
inserts), metal processing (e.g. hot work
tools and dies), space vehicles (eg.
aerodynamically heated skins, rocket
engine parts) heat treating equipments
(e.g. trays, fixtures, conveyor belts,
baskets, fans, furnace mufflers), nuclear
power plants, chemical and petrochemical
industries and heat exchangers.
1.2 MACHINING OF NICKEL BASED
SUPERALLOYS
Nickel based alloys work-harden
rapidly. Work hardening results in
strengthening of the material. Plastic
deformation during machining leads to heat
generation. High temperature gradients are
localized in narrow bands along shear
plane due to poor thermal properties of
Inconel 718, leading to weakening the
material in the deformation zone. When
the rate of thermal softening is greater than
that of strain hardening, material deforms
locally, termed as adiabatic shear failure.
The type of chips formed under these
conditions is termed as shear localized
chips. Oscillations in cutting forces and
high temperatures on the rake face in the
contact area can cause rapid tool wear.
High pressures developed during
segmented chip formation retards further
machining and increase power
requirements of the process.
The method of minimizing work
hardening during machining is to use
sharp tools with a positive rake angle,
control feed rate and depth-of-cut to
2
avoid burnishing. To achieve maximum 1. Major part of the strength is
dimensional stability under difficult maintained during machining due to
machining condition, a given part is their high temperature strength
first rough machined close to size; age properties.
hardened to relieve machining stresses 2. Work hardening occurs rapidly during
and then finished to exact size. Almost machining, contributing to notch wear
any cutting fluid or none can be used in at the tool nose and/or depth-of-cut-line
machining nickel-based superalloys. (DCL).
3. Cutting tools suffer from high abrasive
Water-base fluids are preferred in
wear due to the presence of hard
high speed turning, milling and grinding
abrasive constituents in the superalloy.
because of their greater cooling effect.
4. Chemical reaction occurs at high
For slower operations, such as drilling,
cutting speed when machining
boring, tapping and broaching heavy
with commercially available carbide or
lubricants and very rich mixtures of
cubic boron nitride tools, leading to a
chemical solutions are needed. Tool
high diffusion wear rate.
geometry and machining parameters play
important role in evaluating machining 5. Welding/adhesion of nickel based

efficiency in machining Inconel 718. superalloys onto the cutting tool

Single point cutting tool with positive occurs frequently during machining

rake angles (0⁰ for roughing and 8⁰ for with ceramic tools, causing severe

finishing) are recommended in turning so notching as well as spalling on the

that metal is cut instead of ploughed. tool rake face due to consequent pull

Inconel 718 is very much difficult to out of the tool material.

machine; not many cutting tools can cut 6. Production of a tough and a continuous

this material easily. Ceramic tools and chip, which is difficult to control during

cubic boron nitride tools are machining, enhances degradation of the

recommended for high speed turning (60- cutting tool by seizure and catering.

200 mm/min). Typical feed rates used 7. Poor thermal diffusivity of nickel based

are 0.15 to 0.3 mm/rev and typical depth alloys often generates high temperature

of cuts are 1.0mm to 2.5mm. at the tool tip as well as high thermal
gradients in cutting tool.
Ezugwu et al. summarized the
properties of nickel based superalloys,
1.3 FEM IN METAL CUTTING
contributing to poor machinability as:
Metal cutting is a highly nonlinear
3
 and coupled thermo mechanical process.
The mechanical work is converted into
heat through plastic deformation involved
during the chip formation process in the
primary shear zone. Friction between
chip tool and workpiece tool interface is
another source of heat.
Depending on the machine tool
dynamics, there are variations
machining forces on the residual stresses
in the finished workpiece.
geometry (back and side rake angle,
clearance angle, nose radius) and process
parameters (feed, cutting speed, depth of
cut) are important factors affecting
thermal aspects, residual stresses, and
cutting forces in the metal cutting
process. The experimental approach to
study the effect of all these parameters
on metal cutting process is expensive and
time consuming. These are other tools
available in the form of mathematical
simulations where numerical methods are
applied. Amongst the numerical
procedures, finite-element method (FEM)
is the most frequently used.
In metal cutting process, various
disciplines, such a metallurgy, solid
mechanics (elasticity, plasticity), heat
transfer, tribology (contact problems),
fracture mechanics, and lubrication are
involved. The goal of finite-element
in analysis is to derive reliable
computational models predicting the
Tool deformations, stresses and strains in the
workpiece, as well as the load on the tool
working under specific cutting
parameters.
Most metal cutting processes are
oblique cutting process but orthogonal
cutting process is easier to simulate and
understand the basic mechanics of the
process. Material and geometrical non-
linear analysis, tool wear modelling,
element separation criteria, residual stress
prediction, adaptive meshing are some of
the techniques researchers have been
working

on to improve the reliability of the results stress and strain rate.

of FEM. In many cases the FEM
A large number of technical
simulations have been validated by
papers are published dealing with
comparison with the results of
constitutive models stress-strain
experimental investigations.
relationship. Similarly, the tool/chip
The main advantage of using FEM
interface can be idealized with sticking
compared to other empirical models is its
and sliding friction conditions.
ability to represent workpiece material
Continuous heat generation and elevated
properties as a function of temperature,
temperatures cause reduced wear
4
resistance of tool material and change geometry together with workpiece
in tool geometry and tool size. This residual stress can be predicted.
results in increased cutting forces with
The elements are attached to the
larger deflections in workpiece resulting
workpiece material and chip separation
in chatter. Models are being developed
criteria are used to allow the chip to
for simulation to study the effect of
separate from the workpiece. Various
friction temperature on tools and tool
researchers have proposed different chip
coatings.
separation criteria for FEM simulation in
The major problem encountered machining, which are either classified as
when modelling the effect of tool coating physical or geometric. The physical
on tool performances acquiring realistic criteria include strain energy density,
mechanical property data. Coating effective plastic strain and stress, while
properties, such as adhesion strength and geometric criteria relate to the distance
coefficient of friction obtained from between the overlapping nodes and the
scratch tests must be treated with caution. tool tip. Simulations are also conducted to
This is because such parameters are predict chip flow and chip breaking
dependent on the sliding speed, critical phenomenon
load and temperature used during the Movement and control of chip along
experiment. In addition, the grade of the contact length with the tool are important
substrate on to which the coating is factors for tool wear models. Deformation
deposited influences the mechanical of workmaterial, contact properties,
properties. Consequently, little published friction, large plastic strains, strain-
work on FEM with coated tools is hardening and thermal softening effects
available. play major role in chip formation
mechanism. Simulations for optimum
Advances in computation
design of machine tools and tool geometry
accessories, such as faster processors and
are carried out to provide some practical
larger memory have encouraged
solutions to improve the process output.
researchers to use Lagrangian
formulation for metal cutting Until the mid-1990s, most of the
simulation. The principal advantages of researchers used in-house finite element
this approach are (1) the tool can be code; however, the use of commercial
simulated form some initial state to steady software packages has increased recently.
state cutting condition and (2) the chip General purpose FEM codes capable of

5
 modelling the machining process include effective manner.
NIKE2D, ABAQUS/Standard,
1.4 PROBLEM STATEMENT
ABAQUS/Explicit, ALGOR, FLUENT,
LS DYNA etc. Unfortunately the
Inconel 718 has vast applications in
majority of general purpose FEM codes
high temperature structural regime.
are only applicable for continuous chip
Metallurgical advancements and presence
formation. There are specially developed
of γ” phase, which is stable at high
FEM codes, such as DEFORM2D,
temperature (up to 650° C) have made
FORGED2D, AdantEdge, which are
the metal stronger at high temperatures.
capable of simulating segmented and
But high temperature characteristics of
discontinuous chip formation.
this metal translate directly to machining

Childs et al (2000). summarized the challenges. The combination of high

development and testing of finite element cutting force and high temperature when

techniques for chip formation process machining Inconel 718 leads to tool

since 1970s. Limited availability of chipping or deformation. In addition, a

material properties depending on hardened surface created during machining
temperature and strain rate, lack of may result in depth-of-cut-line (DCL)
reliable friction characteristics and notching of the tool and may also
realistic failure criteria during evolving compromise the fatigue strength and
days of finite element theories for metal geometric accuracy of the part. These
cutting is reported. difficulties limit the cutting speed for the
alloy to the range of 15-30 m/min.
Future ways of finite element modelling of
chip formation were proposed as: Researchers have been attempting to
provide solutions to improve
1. Interactive convergence method for
machinability of the alloy through
steady state processes could be attributed
experimentation, analytical modelling and
to its computing efficiency.
simulations (finite element modeling).
2. Lagrangian adaptive mesh refining
Explanation of cause and effect of the
methods for unsteady processes with
chip segmentation process in machining
elastic- plastic or perfectly plastic
Inconel 718 has been sought by
materials.
researchers over the years. Result in
3. Lagrangian fixed mesh methods with
depth-of-cut-line (DCL) notching of the
chip separation criteria to support the
tool and may also compromise the fatigue
studies of unsteady processes in time
strength and geometric accuracy of the
6
part. These difficulties limit the cutting criterion to explain chip formation
speed for the alloy to the range of mechanism. An attempt is made to
15-30 m/min. Researchers have been alleviate this problem in this study.
attempting to provide solutions to
The objectives of proposed investigation
improve machinability of the alloy are as follows:
through experimentation, analytical
1. To conduct finite element simulations of
modelling and simulations (finite element
machining Inconel 718 and observe chip
modeling). Explanation of cause and
formation mechanism.
effect of the chip segmentation process
2. To apply a material model to represent
in machining Inconel 718 has been
strain, strain rate and temperature
sought by researchers over the years.
dependence of flow stress in the
There are conflicting opinions workmaterial under machining conditions.
regarding the root cause of chip Johnson-Cook constitutive material model
segmentation amongst researchers. Some is formulated in the user subroutine.
of the experimental studies and 3. To apply realistic failure criterion.
computational simulations propose Cockroft & Latham’s criterion for
adiabatic shear failure as reason of catastrophic shear failure is formulated
instability. Others suggest crack initiation and adiabatic shear is considered to be the
and propagation in deformation zone as reason for chip segmentation.
basis of chip segmentation. Focus of this
4. To validate the results of finite
investigation is to present some evidence
element simulations by comparing the
for chip segmentation procedure based on
cutting force, temperature on the rake face
FEM simulation and the chip shape with experimental data

Finite element method provides reported in the literature. To compare chip

means for the study of complex formation process with experimental

machining process in a shorter time and observations and clarifications given by

at a lower cost as compared to Komanduri.

experimental study. The primary concern 5. To simulate orthogonal machining

Inconel 718 at different cutting speeds
in computational study is realistic (from 30 to
representation of material model and 180 m/min), different rake angles (-30°
reliable failure criterion. Literature review to 45°), and different feed rates (0.25 to
for this study has underlined lack of 1.0 mm/rev) to study the effects on chip
reliable material properties and failure segmentation.

7
 6. To predict the cutting speed for onset phenomenon, results, and analyses
chip segmentation.
reported in the literature on the topic are
7. To study the different machining
presented. Literature on finite element
conditions on the cutting and thrust
analysis of machining of difficult-to-
forces, power consumption, shear zone
machine materials to the extent pertinent
temperature rake face temperature and
to the present investigation is reviewed
equivalent plastic strain. and discussed. Chip separation criterion,

Deform 2-D; a commercial finite constitutive material models, material

element software code is used to run properties for these models, friction

the simulations. User subroutine is model are some of the important issues in

developed to incorporate Johnson-Cook the FEM simulation of metal

material model and Recht’s failure cutting. Work reported in the literature
addressing these issues is presented.
criterion in the main code. Current work in
FEM analysis of machining of Inconel 718
1.5 OUTLINE OF THE PROJECT
is discussed.
WORK

In chapter 3, experimental procedure and

This study concentrates on the
the finite element analysis of machining
application of thermoplastic shear
is presented. Material models for
instability theory as chip segmentation
machining simulation are also discussed.
criterion in simulating turning operation
In chapter 4, finite element
of Inconel 718. Finite element method is
simulation approach, and results of this
selected as the simulation tool.
study are presented and the conclusion
Simulations are run using the commercial
arrived from the study is listed in chapter
software
2.CHIP SEGMENTATION IN
‘DEFORM2D’ developed by the MACHINING
scientific Forging Technologies 2.1 THERMOPLASTIC SHEAR
INSTABILITY
Corporation. Effects of various machining
parameters on chip formation process, Thermoplastic instability of the
cutting and thrust forces, temperature workmaterial is considered as the primary
distribution, and stress-strain distribution reason for shear localization and a
(in chip, tool and workpiece) are studied. major contributor to chip segmentation.
Physics based material properties, such
In chapter 2, machinability aspects of
as flow stress depends on strain, strain
Inconel 718, earlier experimental studies,
rate, and temperature of workmaterial.
clarifications on chip segmentation
During complex process of metal
8
cutting these parameters change
rapidly. Materials get strain hardened
due to plastic deformation
machining. Degree of hardening depends
on metallurgy of a particular material.
Similarly, material gets weakened due
to rise in temperature, termed as thermal
softening. These phenomena are governed
by strain hardening exponent
thermal softening coefficient of the
material. In case of nickel-based
superalloys, it is known that γ” phase
gives high strength to material up to 650°
C but destabilizes due to coarsening at
higher temperatures. Due to
phenomenon, material loses its strength at
higher temperatures rapidly.
At low rate of deformation (low
cutting speed), machining process is
isothermal. Thermal energy produced due
to plastic deformation of workmaterial
gets distributed within the system. Plastic
shear strain has its effect on weak shear
zones in the material. Material in these
zones derives its strength by strain
hardening. At high rate of deformation,
temperature gradients are established in
the workmaterial as no time is permitted
for energy transfer. This effect
enhanced by poor thermal properties of
certain difficult-to-cut materials, such as
titanium alloys, nickel-based superalloys,
and hardened steels. These temperature
gradients are formed locally leading to
weakening of material in that zone. This
process is termed as adiabatic shear
during localization. If the rate of thermal
softening exceeds rate of strain hardening,
material continues to deform locally in
that particular zone leading to
catastrophic failure of shear localized
band. This causes instability in the
and cutting process, which is known as
thermoplastic shear instability.
2.2 MECHANISM OF ADIABATIC
SHEAR LOCALIZATION AND THE
CHIP SEGMENTATION PROCESS
Adiabatic shear localization has
been observed in various processes,
this
including, ballistic impact fragmentation
of cylindrical shells, blanking, high-speed
metal forming, and machining of some
materials. The formation of adiabatic
shear band is influenced by the thermo-
physical properties. Some of the
properties, to mention, are specific heat,
thermal conductivity and thermal
diffusivity, strain hardening exponent,
temperature dependence of flow stress,
and density. Yield surface curvature,
which depends on strain hardening and
thermal softening of material, plays an
important role in shear localization
is
process. In machining titanium alloys,
nickel-based superalloys, and hardened
steels at particular speeds, significant
amount of thermal energy is localized
within the highly strained bands. Heat is
generated in the deformation zone due to
9
plastic deformation.
Figure 2.1 Schematic showing the
sequence of events leading to shear
localized chip formation
Komanduri provided some clarifications
on the mechanics of chip formation when
machining titanium alloys. According to
him, the chip segmentation in machining
some of the difficult- to-machine
materials can be divided in two steps,
with the first one being plastic instability
and second being the upsetting process.
As the tool advances, it causes plastic
deformation along the shear surface in
the workmaterial. Surface 5 in Fig. 2.1
represents shear surface with intense
strain localization. This surface originates
from the tool tip and moves parallel to the
cutting speed direction. It gradually
curves with concave surface upwards
until it meets the free chip surface
(surface 1 in Fig. 4.1), which is
undeformed. Gradual flattening of the
softer half wedge occurs in the second
step. This step involves very low
deformation. Build up of the chip
segment starts with this step. Initial
contact length in this step is very short
and increases as flattening progresses. No
relative motion was observed between the
bottom of chip segment being formed and
the tool rake face until the end of the
flattening step. Bulging, also known as
upsetting of the work material can be
observed in the second step. Due to this,
chip segment being formed is pushed
upwards slowly. The stresses begin to
build up in the primary shear zone as
bulging progresses. The contact between
the previous chip segment and the new
chip segment being formed reduces as
flattening progresses. It causes intense
shear in the narrow band between the
two chip segments. Once the shear is
initiated in bulging workmaterial, it
progresses rapidly. At the same time chip
segment is pushed up on rake face.
Periodic development of concentrated
shear band with very large strain
followed by catastrophic shear failure is
known as adiabatic shear failure.
Temperature rise in the newly forming
shear band is moderate during most of the
time in chip segment formation, but it
increases rapidly once the large shear
strains are produced in the shear band.
2.3 EFFECT OF CHIP
SEGMENTATION
Chip segmentation process has
1
0
influence on the dynamics of the along narrow shear bands. Shear angle
metal cutting process. Principal cutting is calculated based on chip thickness and
force increases with progress of upsetting machinability of the material is predicted
step of chip segment formation and based on shear angle. Larger the shear
drops down sharply as catastrophic angle, better the machinability. In case of
shear failure occurs. This process is segmented chip formation, machinability
repeated and can lead to vibrations in the cannot be predicted based on shear angle
machine tool system. With increasing as chip thickness ratio is not a true
cutting speed, the intense shear takes representative of machining efficiency.
place very rapidly leading to very small Freshly formed surface of segmented chip
contact between any two chip segments at high temperatures is in contact with the
and separation of chip segments tool face for a long time as the chip
eventually. This influences fatigue segment moves slowly in the upsetting
loading on the tool and affects tool life phase.
adversely. eventually. This influences
EXPERIMENTAL PROCEDURE
fatigue loading on the tool and affects
tool life adversely. 3. WORKPIECE AND TOOL
MATERIAL
There is neither sticking of the
3.1.1 Inconel 718
chip on the rake face nor shear between
the rake face and the chip, unlike in It is difficult to shape as well as
continuous chip formation. The concept machining Inconel 718 using traditional
of secondary shear can be neglected in techniques due to rapid work
the case of segmented chip formation. hardening. After the first machining
The chip thickness of segmented chip pass, work hardening tends to
formed is less than the continuous chip plastically deform either the workpiece
formed under similar machining or the tool on subsequent passes. For
conditions for easy- to-machine materials. this reason, age-hardened Inconel such
This is due to non-uniform deformation in as 718 are machined using an
machining titanium and nickel-based aggressive but slow cut with a hard tool,
superalloys. Very less deformation is minimizing the number of passes
observed in bulk of chip being formed required.
while major deformation takes place

Table 3.1 Chemical composition of Inconel 718 (%wt)

1
1
Ni Fe Cr Mo Nb Ti Al C Mn Si

52.5 18.5 19 3 5.1 0.9 0.5 0.04 2 0.2

1
2
 Alternatively, the majority of the
machining can be performed with the
workpiece in a solutionized form, with
only the final steps being performed
after age-hardening. External threads are
machined using a lathe to "single
point" the threads, or by rolling the
threads using a screw machine. Holes
with internal threads are made by
welding or brazing threaded inserts made
of stainless steel. Internal threads can
also be formed using EDM machining.
Cutting of a plate is often done with a
water jet cutter. Internal threads can also
be cut by the single point method on a
lathe, or by thread milling on a
machining center. New whisker
reinforced ceramic cutters are also used
to machine nickel alloys. They remove
material at a rate typically eight times
faster than carbide cutters. 718 Inconel
can also be roll threaded after full
aging by using induction heat to
1300°F without increasing the grain
size. Apart from these methods, Inconel
parts can also be manufactured by
selective laser melting. The physical
properties and chemical composition of
Inconel 718 is given in Table 3.1
respectively.
3.1.2 POLYCRYSTALLINE CUBIC
BORON NITRIDE
Cubic Boron Nitride (CBN or c-BN) is
widely used as an abrasive. Its usefulness
arises from its insolubility in iron, nickel,
and related alloys at high temperatures,
whereas diamond is soluble in these
metals to give carbides. Polycrystalline c-
BN (PCBN) abrasives are therefore used
for machining steel, whereas diamond
abrasives are preferred for aluminium
alloys, ceramics, and stone. When in
contact with oxygen at high temperatures,
BN forms a passivation layer of boron
oxide. Boron nitride binds well with
metals, due to formation of interlayers of
metal borides or nitrides. Materials with
cubic boron nitride crystals are often used
in the tool bits of cutting tools. For
grinding applications, softer binders,
e.g. resin, porous ceramics, and soft
metals, are used. Ceramic binders can be
used as well. Commercial products are
known under names "Borazon" (by
Diamond Innovations), and "Elbor" or
thermal conductivity and electrical
resistivity is ideal for heat spreaders.
Contrary to diamond, large c-BN pellets
can be produced in a simple process
(called sintering) of annealing c-BN
powders in nitrogen flow at temperatures
slightly below the BN decomposition
temperature. This ability of c-BN and h-
BN powders to fuse allows cheap
production of large BN parts.
As cubic boron nitride consists of
light atoms and is very robust chemically
and mechanically, it is one of the popular
materials for X-ray membranes: low mass Young’s modulus (GPa) 770
results in small X-ray absorption and good
mechanical properties allow usage of thin Poisson ratio 0.18
membranes, thus further reducing the
absorption. The properties of PCBN tool Specific heat capacity (J/g⁰K) 3.264

material is given in the Table.5.3

Thermal conductivity (W/m- 100
Table 3.2 Properties of PCBN
⁰K)
 "Cubonite" (by Russian vendors). length of 3 mm and depth of cut of 1
Similar to diamond, the combination in mm):
c-BN of highest
1. Cutting speeds: 30.5, 61.0, 91.5,
3.2 EXPERMENTAL SETUP
122.0, 152.5, 183.5 m/min (each with rake
Orthogonal cutting experiments angles of -15°, 0° and 15° at 0.25 mm/rev
were carried out in the Kriloskar MAX5 feed rate) Number of runs : 18
convention lathe machine. The 2. Rake angles: -30°, -15°, 0°, 15°, 30°,
45° (each at 61 m/min cutting speed and
photographic image of experimental
0.25 mm/rev feed rate) Number of runs: 6
setup is shown in the figure 5.1.
3. Feed rates: 0.25, 0.5, 0.75, 1.0
Combination of cutting conditions used mm/rev (each at 61 m/min cutting speed
for simulations is listed below (for cutting and 0°rake angle) Number of runs : 4
 Table 3.3 Johnson-Cook material model constants for Inconel 718.

A[MPa] B[MPa] C N M

1029.1 1477.5 0.0 0.326 1.9

Figure 3.1 Flow stress validation based on J-C material model for Inconel 718 in the
0 0
temperature range of 20 to 1100 C and the strain in the range of 0.005 to 4.0 at
-3 -1
the strain rate of 20X10 S .

17
17
Figure 3.2 Temperature and strain dependence of flow stress governing parameters forJ-
C model of Inconel 718.

18
18
 Orthogonal machining of Inconel chip formation are cutting speed, depth of
718 is simulated using Deform 2D, cut, feed rate and tool normal rake angle.
explicit, Lagrangian formulation finite Depth of cut and cutting speed for a
element code. User subroutine is particular simulation are assumed to be
developed to apply Johnson- Cook constant for that run. Adiabatic
material model and Recht’s failure temperature boundary conditions are
criterion in the main code. assumed. Effect of any cooling material is
not investigated in this study. The
Metal cutting is affected by the
machining operation is assumed to be
type of workmaterial, tool material and
performed in air without application of any
cutting conditions. The factors affecting
liquid coolants. Combination of cutting
chip formation are cutting speed, depth of
conditions used for simulations is listed
cut, feed rate and tool normal rake angle.
below (for cutting length of 3 mm and
Depth of cut and cutting speed for a
depth of cut of 1 mm):
particular simulation are assumed to be
constant for that run. Adiabatic
1. Cutting speeds: 30.5, 61.0, 91.5, 122.0,
temperature boundary conditions are
152.5, 183.5 m/min (each with rake angles
assumed. Effect of any cooling material is
of -15°, 0° and 15° at 0.25 mm/rev feed
not investigated in this study. The
rate) Number of runs : 18
machining operation is assumed to be
2. Rake angles: -30°, -15°, 0°, 15°, 30°,
performed in air without application of 45° (each at 61 m/min cutting speed and
any liquid coolants 0.25 mm/rev feed rate) Number of runs: 6
3. Feed rates: 0.25, 0.5, 0.75, 1.0 mm/rev
4.RESULTS & DISCUSSIONS (each at 61 m/min cutting speed and 0°
rake angle) Number of runs : 4
Orthogonal machining of Inconel
718 is simulated using Deform 2D, Prediction of the onset of chip
implicit, Lagrangian formulation finite segmentation under different machining
element code. User subroutine is conditions is another objective of this
developed to apply Johnson- Cook investigation. The effect of different
material model and Recht’s failure machining conditions on cutting force,
criterion in the main code. thrust force, power consumed during
machining, shear zone temperatures and
Metal cutting is affected by the
rake face temperatures are observed by
type of workmaterial, tool material and
post processing the FEM simulation
cutting conditions. The factors affecting
results.
19
19
 to validate the Johnson-Cook material
5. COMPARISON OF RESULTS WITH
EXPERIMENTAL DATA model and Cockroft & Latham’s
catastrophic shear failure criterion
This investigation involves application of
combination used in this study. Results of
material model which has been used with
finite element simulations of machining
other failure criteria earlier. It is important
of Inconel 718 reported in the literature

20
20
Figure 5.1 Results of rake face temperature observed at various cutting speeds in
FEM simulation and experimental studies.

Figure 5.2 Average cutting forces observed at a range of cutting speed (30.5 to 183.5
m/min) in FEM simulations and empirical studies.

21
21
 Figure 5.3 Thrust force observed at a range of cutting speeds (30.5 to 183.5
m/min) in FEM simulation and experimental studies of machining Inconel 718.

6. CONCLUSION

Chip segmentation is observed in rake tools. Number of chip segments is

simulations at all cutting speeds above not observed to vary much for
61.0 m/min and zero or negative rake simulations with 0° rake tools but
tools. A comparison of the tool rake face intensity of shear localization is observed
temperatures obtained in the FEM to increase with increasing cutting speed.
simulation found a good match with Chip segments with much narrow shear
machining test data with maximum error localized bands are observed in
of 12.6%. Results for cutting force are simulations of machining with higher feed
compared with the experimental are rates.
within an error margin of 19.5%. Results Cutting force and thrust force are
for thrust force are compared with the observed to increase gradually during the
experimental results and are within an upsetting stage of chip formation process
error margin of 2.7%. and drop sharply as shear failure takes
Shear localization is not observed place. Cutting forces and thrust forces
in the simulations with positive rake are observed to reduce with increasing
angle tool at the cutting speeds used. cutting speed and with increasing rake
Number of highly strained shear bands angles but increase significantly with
and chip segments are observed to increasing feed rate.
increase with increasing cutting speed in REFERENCES
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33