Multi-Scale Fe Modeling On INCONEL718 Orthogonal Cutting Process

Inconel718 is widely used in gas turbines and aircraft engines due to its high strength properties at high temperature and high corrosion resistance. With the development of modern manufacturing industry, the airplane and nuclear facilities make a higher requirement for the safety-critical components. So the optimal analysis of Inconel718 cutting process has become very important. Inconel718 material falls into three groups: nickel, iron and brittle phases (TiC, NbC) which present a random distribution in the matrix. The brittle particles cause unstable cutting process and severe tool abrasion which are unfavorable for application of Inconel718. So it is very important to perform some research on metal cutting mechanism of Inconel718. This paper aims to optimize the cutting performance through experimental design and FEA. Then based on adhesive wear and abrasive wear theory, the wear length of flank of cutting tool is calculated which provides theoretical foundation and technical support for cutting Inconel718.Firstly, a FE model of orthogonal machining Inconel718 is established considering the plough effect of round cutting edge. A cutting experiment under the same cutting conditions adopted in the FE model is conducted to determine the parameters used in FE model and to validate the accuracy of the FE model. The comparisons between simulation and experimental cutting force and chip morphology demonstrate that the established model is accurate. Meanwhile, effects of different cutting conditions including different cutting speed and feed rate on temperature distribution and cutting force are investigated in the machining process. Then the plough effect and rake face extrusion on the machining process are studied.Secondly, a FE model of orthogonal machining Inconel718 is established considering one particle. To evaluate the impact of particles on the sub-surface of Inconel718 in high-speed cutting process, a cohesive element technique is adopted to predict particle crack initiation process. The influence of particles sizes and depths on the particle crack initiation and the cutting process are investigated based on the Multi-scale model. a 3D FE model is established to study the effect of interface stiffness between particle and Inconel718 on the particle crack initiation and the cutting process.A microscopic picture of Inconel718 is obtained by means of metallographic phase analysis. Matlab and python are used to create Inconel718 microstructure based on the SEM picture. A multi-scale orthogonal cutting FE model is established based on the microstructure from micro to meso scale. The multi-scale FE model is validated with experimental data and Inconel718 FE model in terms of cutting forces and chip morphology. Based on the results of multi-scale FE model and adhesive wear and abrasive wear theory, the wear length of flank of cutting tool formula is predicted.