Modelling and Finite Element Simulation of Ball-End Milling for Nickel-Based Superalloy Inconel 718

Abstract

Comprehensive exploration of ball-end milling processes is presented in this paper, with a primary focus on the modelling of milling forces and the execution of finite element analysis during the machining of Inconel 718, a material known for its challenging machinability. A detailed milling force model, considering various parameters such as cutting speeds, feed rates, and depths of cut, has been developed, providing valuable insights into the optimization of machining parameters. Temperature and stress distributions within the tool during milling, particularly in the context of difficult-to-machine materials like Inconel 718, were investigated through finite element analysis. Critical temperature profiles at the tool tip, rake face, and flank face, which have an impact on tool wear and lifespan, were identified through the temperature field analysis. Notably, a maximum tool tip temperature of 682 °C was observed during the machining of Inconel 718. Challenges posed by difficult materials were unveiled through the stress field analysis, aiding in stress mitigation and enhancing the understanding of machining processes. In conclusion, a significant contribution is made by this paper to the understanding of ball-end milling processes.