Physics based modeling of machining Inconel 718 to predict surface integrity modification

Rinaldi, Sergio; Imbrogno, Stano; Rotella, Giovanna; Umbrello, Domenico; Filice, Luigino

doi:10.1016/j.procir.2019.04.150

Cited by 18 publications

(8 citation statements)

References 12 publications

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“…Such a laser contour movement is absent for M-IF. Second reason, machining of Inc718 alloy causes machining-induced strain hardening and grain refinement beneath machined surface (Rinaldi et al , 2019). Although this deformation is not as strong as the one induced by SPD process, the existence of plastic deformation, slip activity, dislocation movement and dynamic recrystallization was also suggested (Rinaldi et al , 2019).…”

Section: Discussionmentioning

confidence: 99%

“…Second reason, machining of Inc718 alloy causes machining-induced strain hardening and grain refinement beneath machined surface (Rinaldi et al, 2019). Although this deformation is not as strong as the one induced by SPD process, the existence of plastic deformation, slip activity, dislocation movement and dynamic recrystallization was also suggested (Rinaldi et al, 2019). The average grain size in M-IF (13.1 6 1.7 mm) is almost 26% less than that of HT Figure 13 Longitudinal micro-strain (« y ) map for M-IF sample at various stress levels a) 500 MPa; b) 750 MPa; c) 974 MPa (17.86 6 10.65) demonstrating a very small standard deviation supports the idea of grain refinement as results of machining process.…”

Section: Samples With Ifmentioning

confidence: 99%

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The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

Isik,

Emami Tabrizi,

Khan

et al. 2023

RPJ

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Purpose In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare the structural and mechanical properties of additively manufactured and conventionally machined IFs. Design/methodology/approach In this study, mechanical and microstructural properties of Inconel 718 (Inc718) alloy internal features, manufactured either as-built with AM or machining of additively manufactured (AMed) part thereafter were investigated. Findings The results showed that the average ultimate tensile strength (UTS) of additively manufactured center internal feature (AM-IF) is almost analogous to the machined internal feature (M-IF). However, the yield strength of M-IF is greater than that of AM-IF due the greater surface roughness of the internal feature in AM-IF, which is deemed to surpass the effect of microstructure on the mechanical performance. The results of digital image correlation (DIC) analysis suggest that AM-IF and M-IF conditions have similar strain values under the same stress levels but the specimens with as built IF have a more locally ductile region around their IF, which is confirmed by hardness test results. But this does not change global elongation behavior. The microstructural evolution starting from as-built (AB) and heat-treated (HT) samples to specimens with IF are examined. The microstructure of HT specimens has bimodal grain structure with d phase while the AB specimens display a very fine dendritic microstructure with the presence of carbides. Although they both have close values, machined specimens have a higher frequency of finer grains based on SEM images. Originality/value It was shown that the concurrent creation of the IF during AM can provide a final part with a preserved ultimate tensile strength and elongation but a decreased yield strength. The variation in UTS of AM-IF increases due to the surface roughness near the internal feature as compared to smooth internal surfaces in M-IF. Hence, the outcomes of this study are believed to be valuable for the industry in terms of determining the appropriate production strategy of parts with IF using AM and postprocessing processes.

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Section: Discussionmentioning

confidence: 99%

Section: Samples With Ifmentioning

confidence: 99%

The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

Isik,

Emami Tabrizi,

Khan

et al. 2023

RPJ

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“…IN718 parts maintain their mechanical properties up to 650°C due to the presence of strengthening phases [22]. As a consequence of its mechanical properties and low thermal conductivity, it is classi ed as a di cult material to machine [23,24]. While machining IN718, the low thermal conductivity and rapid work hardening rate result in elevated temperature leads to excessive tool wear [25].…”

Section: Introductionmentioning

confidence: 99%

Tool Life and Surface Integrity Characteristics of SLM and C&W Inconel 718 in Dry and MQL Condition

Periane

Duchosal

Vaudreuil

et al. 2022

Preprint

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In this paper, a tool life test was performed using PVD coated insert on Inconel 718 (IN718) samples. The tool life was tested on IN718 workpiece fabricated through conventional (Cast & Wrought) and additive (Selective Laser Melting) process routes. The as-built SLM samples were subjected to two heat treatments such as Hot Isostatic Pressing (HIP) and Aeronautic Heat Treatment (AHT). This study aimed to evaluate the machining behavior of C&W and SLM IN718 from the machining point of view such as tool wear, chip appearance, surface roughness, and residual stresses. The tool life tests were performed under a dry and near dry environment like using Minimum Quantity Lubrication (MQL). Meanwhile, the tool wear propagation under different cutting conditions is also explored. Under both the cutting conditions flank wear and fracture of the cutting edge are the most predominant failure modes minimizing the tool life. The microhardness, surface roughness, and residual stress measurements were analyzed. The result indicates that the microstructural difference between the C&W and SLM has more influence on the tool life compared to the machining environment. On machining, the SLM sample has 80% and 43% more tool life than the C&W in dry and MQL machining. Comparing the dry and MQL machining of SLM, on using MQL the tool life is 30% less compared to the dry machining.

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“…Modern high-performance materials, such as nickel-based alloys, are constantly improved to manifest higher resistance to cyclic thermo-mechanical loads and oxidation, in order to operate under elevated temperatures for prolonged periods of time. In particular, among these alloys, stands out Waspaloy, for its even superior performances [1,2].…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Waspaloy orthogonal hard machining simulation, a comparison among different rheological models

Rinaldi¹,

Umbrello²

2021

Esaform 2021

Self Cite

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Nickel based superalloys, such as Waspaloy, are extensively used to manufacture components that operate under high temperature cyclic loads, because of their superior chemical and thermo-mechanical properties. In particular, these artifacts are mainly produced by shaping and/or finishing machining operations. Despite of their huge properties, these alloys show an extremely poor workability, that makes them part of the group of the so called difficult-to-cut materials. Therefore, the proper selection of the machining conditions is always challenging for the designers. In this context, predictive models represent an extremely useful tool to numerically simulate the machining process, guaranteeing a good knowledge of the material behavior under machining conditions, and avoiding expansive and time consuming experimental campaigns. Besides, the proper selection of the material rheological model is of fundamental importance in order to obtain precise and affordable results from the numerical model. In this work a Johnson-Cook based viscoplastic flow behavior model was proposed. The model was obtained from Artificial Neural Network (ANN) based interpolation techniques and validated using orthogonal machining experimental tests. Moreover, the proposed model was compared with other rheological models available from literature to benchmark their affordability and assessing their performances.

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Physics based modeling of machining Inconel 718 to predict surface integrity modification

Cited by 18 publications

References 12 publications

The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

Tool Life and Surface Integrity Characteristics of SLM and C&W Inconel 718 in Dry and MQL Condition

Waspaloy orthogonal hard machining simulation, a comparison among different rheological models

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Physics based modeling of machining Inconel 718 to predict surface integrity modification

Cited by 18 publications

References 12 publications

The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

Tool Life and Surface Integrity Characteristics of SLM and C&amp;W Inconel 718 in Dry and MQL Condition

Waspaloy orthogonal hard machining simulation, a comparison among different rheological models

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Product

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Tool Life and Surface Integrity Characteristics of SLM and C&W Inconel 718 in Dry and MQL Condition