FEM analysis on face milling of Inconel 718

Chan, Chee Hoong (2017) FEM analysis on face milling of Inconel 718. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

	Text (24 Pages) FEM Analysis On Face Milling Of Inconel 718 - Chan Chee Hoong - 24 pages.pdf - Submitted Version Download (269kB)
	Text (Full Text) FEM analysis on face milling of Inconel 718.pdf - Submitted Version Restricted to Repository staff only Download (2MB)

Abstract

Problems to machine Inconel 718 has been increasing due to its high toughness and work hardening nature of the alloy. In addition, the machining of Inconel 718 requires a very high cost due to the material is very expensive and time consuming. It causes several problems and restrictions to the researchers. Inconel 718 is a nickel-based superalloy which can withstand high temperature and corrosion resistant. TiAlN coated carbide inserts were used as the cutting tool. The main purpose of this project is FEM analysis on face milling of Inconel 718. This also includes a study on the effect of cutting parameters on resultant force and tool temperature. The cutting parameters are in the range of cutting speeds from 20 to 40 m/min at a range of feed rates from 0.10 to 0.20 mm/tooth and depth of cut in the range of 0.1 to 0.2 mm. The experimental approach was done by using Analysis of Variance (ANOVA) and Response Surface Methodology (RSM). From the results, it was observed that the significant factors which affect the resultant force are feed rate and depth of cut, while cutting speed has no significant difference in resultant force. Interaction between feed rate and depth of cut has the most influence on resultant force. On the other hand, the significant factors that affect tool temperature are cutting speed, feed rate and depth of cut. Through RSM method, the optimal parameters set obtained was 23.13 m/min, 0.10 mm/tooth and 0.10 mm for cutting speed (Vc), feed rate (fz), depth of cut (ap) respectively. The simulated results were then validated with actual experiment. It is found that the percentage of relative error between FEM simulation and actual experiment for resultant force and tool temperature are 10% and 31% respectively. By considering all the possible errors, the overall trend of the simulated result shows a reasonably good agreement with the experimental result.

Actions (login required)

View Item