A 2D Finite Element Model set up using the Arbitrary Lagrangian Eulerian (A.L.E) formulation proposed in Abaqus/Explicit© (v6.8) is employed to analyze the sensitivity to material input parameters and cutting speed when predicting serrated chip in cutting process. No artificial criterion is employed to create the chip or to initiate serrated chip formation. Results showed significant influence of the thermal parameters (thermal conductivity, specific heat and inelastic heat fraction) and material behaviour law (Johnson-Cook law coefficients) on the serrated chip phenomena, especially in the case of the thermal conductivity and specific heat, but as well for parameters no so mentioned in previous research like the strain hardening or the yield stress.

Heat-resistant alloys like Inconel 718 are used in critical components such as aircraft engine turbine discs. Surface integrity is a critical issue in this kind of components and specially residual stresses are a key aspect. Currently, the development and optimization of the machining process with regards to the residual stresses is done through expensive experimental trial and error methods. This article shows the research work made on the development of a machining model in three dimensions with the finite element code Abaqus / ExplicitTM aiming to predict residual stresses. Results obtained in different working conditions are compared with those of commercial programs as DeformTM and AdvantEdgeTM, so as with experimental results obtained in turning. The results obtained show on the influence of working conditions (cutting speed, feed per revolution) on the cutting forces and temperatures and the high degree of qualitative agreement with finite element modeling in the generation of surface residual stress.

Heat-resistant alloys like Inconel 718 are used in critical components such as aircraft engine turbine discs. Due to the extreme thermo-mechanical solicitations that must suffer during their lifetime, reliability is essential, even more if its failure could lead to loss of human lives. Surface integrity is a critical issue in this kind of components and especially residual stresses are a key aspect. Currently, the development and optimization of the machining process with regards to the residual stresses is done through expensive experimental trial and error methods. This article shows the research work made on the simulation of a machining model in three dimensions with the DeformTM commercial program. The results obtained show the influence of contact parameters (friction coefficient, heat transfer coefficient) not only on the cutting forces and temperatures, but also in the generation of residual stresses.

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