Simulation of cutting force during high speed end milling of inconel 718

Ganesan, Hema Nanthini (2015) Simulation of cutting force during high speed end milling of inconel 718. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The essentials understanding of metal cutting processes over the experimental studies have several problems and restrictions. The understanding of machining process under different cutting parameters is better in machining modeling. Inconel is a nickel-based super alloy, prominently well-known as a difficult-to-cut material. It possesses great strength and corrosion resistant and withstand at elevated temperature (900 -1050◦ C). The main aim of this study is FEM simulation of cutting force during high speed end milling of Inconel 718 under dry machining condition. TiAlN/AlCrN-coated carbide inserts was used as the cutting tool for the machining simulation. The investigated milling parameters were cutting speed (100-140 m/min), feed rate (0.1-0.2 mm/tooth) and axial depth of cut (0.5 – 1.0 mm). The DEFORM 3D software is used as a simulation tool for achieved the goal of this study. This project describes a study on the cutting parameter effect on cutting force, feed force and thrust force during simulation of high speed end milling of Inconel 718. The simulation results on cutting force, feed force and thrust force are compared with experimental results to achieve the accuracy. The comparison made between simulation and experimental results specify that, the average error of cutting force (Fx) is 258.34N, feed force (Fy) is 61.28N and thrust force (Fz) is 82.10N. It was found that, the low cutting force was obtained during the lowest depth of cut and lowest feed rate. The significant parameter that can be used to obtain low cutting force, feed force and thrust force during high speed end milling of Inconel 718 are Vc = 120.58m/min, fz = 0.13mm/tooth and ap = 0.98mm.

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