Effects of Cutting Edge Microgeometry on Residual Stress in Orthogonal Cutting of Inconel 718 by FEM

Shen, Qi; Wang, Qingqing; Hua, Yang; Zhao, Jiaqi; Lv, Woyun; Mohsan, Aziz Ul Hassan

doi:10.3390/ma11061015

Cited by 34 publications

(9 citation statements)

References 30 publications

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“…The distribution trend of residual stress along the negative Y-axis in the turned shallow surface is approximately hook-shaped for Inconel 718 material [ 26 ], as exhibited in Figure 3 a. The cutting process is coupled with thermal-mechanical loads.…”

Section: Methodsmentioning

confidence: 99%

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Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations

et al. 2021

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The surface residual stress after machining, especially for finishing, has a vital influence on the shape stability and fatigue life of components. The current study focuses on proposing an original empirical equation to predict turned surface residual stress for Inconel 718 material, taking tool parameters into consideration. The tool cutting-edge angle, rake angle, and inclination angle are introduced for the first time in the equation based on the Inconel 718 material turning experiments and finite element simulations. In this study, the reliability of simulation parameters’ setting is firstly calibrated by comparing the residual stresses and chips of the experiments and simulations. The changing trends of turned forces, temperatures of lathe tool nose, and surface residual stress with turning parameters are analyzed. Then, the predictive equation of surface residual stress is proposed considering relationships between the back-rake angle, the side-rake angle, and the tool cutting-edge angle, rake angle, and inclination angle. Moreover, the genetic algorithm optimizes the objective function to obtain the undetermined coefficients in the prediction equation. Finally, the predicted accuracy of the surface residual stress is proven by comparing the experimental, simulation, and prediction values. The results indicate that the predictive equation of surface residual stress has a good accuracy in predicting turned surface residual stress for Inconel 718 materials. The correlation coefficient, R, and absolute average error between the predicted and the simulated value are 0.9624 and 13.40%, respectively. In the range of cutting parameters studied and experimental errors, this study provides an accurate predictive equation of turned surface residual stress for Inconel 718 materials.

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Section: Methodsmentioning

confidence: 99%

“… ( a ) The hook-shaped tendency of residual stress in the shallow surface [ 26 ]. ( b ) The cutting forces in the turning simulations.…”

Section: Figurementioning

confidence: 99%

Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations

et al. 2021

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“…The effect of the tool material and edge preparation had the greatest percentage contribution to flank wear [20]. Qi Shen et al [21] investigated the effect of cutting edge microgeometry on residual stresses by FEM. The results from the numerical experiment stated that an increase in the size of the cutting edge radius caused enhanced values of the surface tensile residual stress.…”

Section: Introductionmentioning

confidence: 99%

The Tool Life and Coating-Substrate Adhesion of AlCrSiN-Coated Carbide Cutting Tools Prepared by LARC with Respect to the Edge Preparation and Surface Finishing

et al. 2020

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Nanocomposite AlCrSiN hard coatings were deposited on the cemented carbide substrates with a negative substrate bias voltage within the range of −80 to −120 V using the cathodic arc evaporation system. The effect of variation in the bias voltage on the coating-substrate adhesion and nanohardness was investigated. It was clear that if bias voltage increased, nanohardness increased in the range from −80 V to −120 V. The coating deposited at the bias voltage of −120 V had the highest nanohardness (37.7 ± 1.5 GPa). The samples were prepared by brushing and wet microblasting to finish a surface and prepare the required cutting edge radii for the tool life cutting tests and the coating adhesion observation. The indents after the static Mercedes indentation test were studied by scanning the electron microscope to evaluate the coating-substrate adhesion. The longer time of edge preparation with surface finishing led to a slight deterioration in the adhesion strength of the coating to the substrate. The tool wear of cemented carbide turning inserts was studied on the turning centre during the tool life cutting test. The tested workpiece material was austenitic stainless steel. The cemented carbide turning inserts with larger cutting edge radius were worn out faster during the machining. Meanwhile, the tool life increased when the cutting edge radius was smaller.

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“…Using the experimental and numerical investigation, Madariaga et al [22] reported that tool wear remarkably changes surface residual stress in face turning of Inconel 718. The influence of cutting edge geometry was numerically investigated in 2D modeling of Inconel 718 cutting by Shen et al [23]. They found that more tensile residual stresses are induced in superficial layers, when chamfered tool is used.…”

Section: Introductionmentioning

confidence: 99%

3D modeling of recrystallized layer depth and residual stress in dry machining of nickel-based alloy

Jafarian¹

2019

J Braz. Soc. Mech. Sci. Eng.

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Surface integrity is one of the important requirements of engineers, and it should be controlled for manufacturing of different components. Among different indications of surface integrity, metallurgical aspects including microstructure changes and residual stresses are remarkably effective on performance and service life of the products. Machining process of Inconel 718 alloy is widely used in advanced industries, and therefore, surface integrity of machined workpieces is essential task. Since experimental investigation in this subject is really difficult and time-consuming, finite element modeling of machining processes is used as beneficial method. In this paper, 3D analysis of machining process of Inconel 718 alloy was carried out to evaluate surface integrity in terms of depth of the recrystallized layer and residual stress. At first section, experimental tests were conducted at different machining process to use them as the benchmark for evaluation of recrystallized layer depth in machining simulation. Using the critical strain criterion, the numerical results of recrystallized layer depth was calculated and successfully verified with corresponding experiments. To improve precision of the numerical results, the user subroutine was implemented in FE code to employ hardness-based flow stress and also cutting tool geometry was precisely measured. At the second section, residual stress distribution in the machined surface was firstly predicted using the elastic-plastic analysis and verified with experimental test. After that, the effect of testing conditions was evaluated and discussed on different indications of residual stress profile. Finally, there is reasonable hope that utilized strategy can be extended efficiently for other manufacturing processes.

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Effects of Cutting Edge Microgeometry on Residual Stress in Orthogonal Cutting of Inconel 718 by FEM

Cited by 34 publications

References 30 publications

Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations

Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations

The Tool Life and Coating-Substrate Adhesion of AlCrSiN-Coated Carbide Cutting Tools Prepared by LARC with Respect to the Edge Preparation and Surface Finishing

3D modeling of recrystallized layer depth and residual stress in dry machining of nickel-based alloy

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