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Finite Element Investigation of Material Models in Machining Simulation of Inconel 718 Dr.R.Rajappan, D.Anbuselvan
Finite Element Investigation of Material Models in Machining Simulation of Inconel 718 Dr.R.Rajappan, D.Anbuselvan
Finite Element Investigation of Material Models in Machining Simulation of Inconel 718 Dr.R.Rajappan, D.Anbuselvan
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
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aerodynamically heated skins, rocket
1.INTRODUCTION
engine parts) heat treating equipments
Nickel-based super alloy (e.g. trays, fixtures, conveyor belts,
development of aerospace began in the baskets, fans, furnace mufflers), nuclear
1930s. Need for the more creep resistant power plants, chemical and petrochemical
material than the available austenitic industries and heat exchangers.
stainless steel propelled research to
develop new superalloy. The principal 1.2 MACHINING OF NICKEL BASED
SUPERALLOYS
characteristics of nickel as an alloy base
are highly phase stability of face centered Nickel based alloys work-harden
cubic(FCC) nickel matrix and rapidly. Work hardening results in
outstanding strength retention up to strengthening of the material. Plastic
0.7Tm (melting point). These deformation during machining leads to heat
characteristics encourage use of nickel generation. High temperature gradients are
based superalloys in vast number of localized in narrow bands along shear
applications subjected high temperatures. plane due to poor thermal properties of
Commercially available nickel base Inconel 718, leading to weakening the
superalloys include Inconel, Nimonic, material in the deformation zone. When
Rene, Udimet, and Pyromet. Inconel 718 the rate of thermal softening is greater than
is the most frequently used nickel based that of strain hardening, material deforms
superalloys; hence this study is focused locally, termed as adiabatic shear failure.
on an investigation into the mechanics of The type of chips formed under these
machining Inconel 718. conditions is termed as shear localized
chips. Oscillations in cutting forces and
1.1 APPLICATIONS OF NICKEL-BASED
SUPERALLOYS high temperatures on the rake face in the
contact area can cause rapid tool wear.
Some of the applications of nickel High pressures developed during
based superalloys are in aircraft gas segmented chip formation retards further
turbines (e.g. disks, combustion chamber, machining and increase power
casings, shafts, exhaust system, blades, requirements of the process.
vanes, burner, cans, stack gas reheaters),
reciprocating engines (e.g. turbochargers, The method of minimizing work
exhaust valves hot plugs, valve seat hardening during machining is to use
inserts), metal processing (e.g. hot work sharp tools with a positive rake angle,
tools and dies), space vehicles (eg. control feed rate and depth-of-cut to
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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
Single point cutting tool with positive occurs frequently during machining
rake angles (0⁰ for roughing and 8⁰ for with ceramic tools, causing severe
that metal is cut instead of ploughed. tool rake face due to consequent pull
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
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
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and coupled thermo mechanical process. procedures, finite-element method (FEM)
The mechanical work is converted into is the most frequently used.
heat through plastic deformation involved
In metal cutting process, various
during the chip formation process in the
disciplines, such a metallurgy, solid
primary shear zone. Friction between
mechanics (elasticity, plasticity), heat
chip tool and workpiece tool interface is
transfer, tribology (contact problems),
another source of heat.
fracture mechanics, and lubrication are
Depending on the machine tool involved. The goal of finite-element
dynamics, there are variations in analysis is to derive reliable
machining forces on the residual stresses computational models predicting the
in the finished workpiece. Tool deformations, stresses and strains in the
geometry (back and side rake angle, workpiece, as well as the load on the tool
clearance angle, nose radius) and process working under specific cutting
parameters (feed, cutting speed, depth of parameters.
cut) are important factors affecting
Most metal cutting processes are
thermal aspects, residual stresses, and
oblique cutting process but orthogonal
cutting forces in the metal cutting
cutting process is easier to simulate and
process. The experimental approach to
understand the basic mechanics of the
study the effect of all these parameters
process. Material and geometrical non-
on metal cutting process is expensive and
linear analysis, tool wear modelling,
time consuming. These are other tools
element separation criteria, residual stress
available in the form of mathematical
prediction, adaptive meshing are some of
simulations where numerical methods are
the techniques researchers have been
applied. Amongst the numerical
working
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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
development and testing of finite element cutting force and high temperature when
techniques for chip formation process machining Inconel 718 leads to tool
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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,
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
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
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Ni Fe Cr Mo Nb Ti Al C Mn Si
1
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Alternatively, the majority of the widely used as an abrasive. Its usefulness
machining can be performed with the arises from its insolubility in iron, nickel,
workpiece in a solutionized form, with and related alloys at high temperatures,
only the final steps being performed whereas diamond is soluble in these
after age-hardening. External threads are metals to give carbides. Polycrystalline c-
machined using a lathe to "single BN (PCBN) abrasives are therefore used
point" the threads, or by rolling the for machining steel, whereas diamond
threads using a screw machine. Holes abrasives are preferred for aluminium
with internal threads are made by alloys, ceramics, and stone. When in
welding or brazing threaded inserts made contact with oxygen at high temperatures,
of stainless steel. Internal threads can BN forms a passivation layer of boron
also be formed using EDM machining. oxide. Boron nitride binds well with
metals, due to formation of interlayers of
Cutting of a plate is often done with a
metal borides or nitrides. Materials with
water jet cutter. Internal threads can also
cubic boron nitride crystals are often used
be cut by the single point method on a
in the tool bits of cutting tools. For
lathe, or by thread milling on a
grinding applications, softer binders,
machining center. New whisker
e.g. resin, porous ceramics, and soft
reinforced ceramic cutters are also used
metals, are used. Ceramic binders can be
to machine nickel alloys. They remove
used as well. Commercial products are
material at a rate typically eight times
known under names "Borazon" (by
faster than carbide cutters. 718 Inconel
Diamond Innovations), and "Elbor" or
can also be roll threaded after full
thermal conductivity and electrical
aging by using induction heat to
resistivity is ideal for heat spreaders.
1300°F without increasing the grain
Contrary to diamond, large c-BN pellets
size. Apart from these methods, Inconel
can be produced in a simple process
parts can also be manufactured by
(called sintering) of annealing c-BN
selective laser melting. The physical
powders in nitrogen flow at temperatures
properties and chemical composition of
slightly below the BN decomposition
Inconel 718 is given in Table 3.1
temperature. This ability of c-BN and h-
respectively.
BN powders to fuse allows cheap
3.1.2 POLYCRYSTALLINE CUBIC
production of large BN parts.
BORON NITRIDE
A[MPa] B[MPa] C N M
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 .
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Figure 3.2 Temperature and strain dependence of flow stress governing parameters forJ-
C model of Inconel 718.
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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.
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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
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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.
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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