Dry machining of Inconel 718 super alloys using uncoated tool: Experimental and numerical analysis

Aerospace super alloy Inconel 718 is difficult to process through conventional machining operation. Alloys with high strength at high temperatures and high strain hardening, high chemical affinity (towards tool material, and Co binder) etc. impose adverse effects towards smooth machining. Poor thermal conductivity of Inconel 718 promotes excessive temperature rise at the chip-tool interface which causes rapid tool wear, and degraded surface integrity of the end product. Adequate understanding of machining process phenomena along with precise control of machining parameters may yield satisfactory result. Trial, and error experimentation is indeed uneconomical; hence, in the present reporting, Finite Element (FE) based numerical simulation is attempted to model machining responses in the extent of cutting force, tool-tip temperature, depth of flank wear progression, chip-tool contact length, and finally, chip reduction coefficient. Simulation results are verified through experimental tests. Simulation results are found in good agreement with experimental results. Therefore, simulation results can reliably be used as an alternative instead of actual experimental effort.