Investigation of mechanical and thermal loads in pcBN tooling during machining of Inconel 718

Agmell, Mathias; Bushlya, Volodymyr; M’Saoubi, Rachid; Gutnichenko, Оleksandr; Zaporozhets, O. I.; Laakso, Simo; Ståhl, Jan Eric

doi:10.1007/s00170-020-05081-8

Cited by 31 publications

(14 citation statements)

References 24 publications

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“…The boundary conditions for the steady-state heat transfer analysis are shown in Figure 4. It was reported [27,28] that the measured tool side face temperature was 10-30% less than the mid-plane tool temperature. Therefore, the boundary conditions for the contact area of the tools were set to 900 • C, 950 • C, and 1200 • C for the rake angle of 10 • , 0 • , and −10 • , respectively, according to the experimentally measured temperature distribution.…”

Section: Numerical Prediction Of Cutting Force and Temperaturementioning

confidence: 93%

Investigation of the Influence of Tool Rake Angles on Machining of Inconel 718

Liang

Yang

et al. 2021

JMMP

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It is essential for superalloys (e.g., Inconel 718) to obtain an anticipated surface integrity after machining, especially for safety critical areas (e.g., aerospace). As one of the main characteristics for cutting tools, the rake angle has been recognized as a key factor that can significantly influence the machining process. Although there are large research interests and outcomes in the machining of nickel-based superalloys, most of them focus on the surface integrity and macroscale temperature observation, whereas the temperature distribution in the tool rake face is not clear. Thus, it is necessary to investigate the basic role of rake angles and the tool–workpiece interaction mechanism to determine the machining condition variations and surface integrity. In the present study, both experimental and numerical methods are employed to explore the cutting force, thermal distribution, and shear angles during the process and the metallurgy characteristics of the subsurface after machining, as well as the mechanical properties. The research has emphasized the importance of rake angles on both the cutting process and machined surface integrity, and has revealed the microscale temperature distribution in the tool rake face, which is believed to have a close relationship with the tool crater wear. In addition, it is clearly presented that the surface generated with positive rake angle tools generates the minimum subsurface deformation and less strain hardening on the workpiece.

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Section: Numerical Prediction Of Cutting Force and Temperaturementioning

confidence: 93%

Investigation of the Influence of Tool Rake Angles on Machining of Inconel 718

Liang

Yang

et al. 2021

JMMP

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“…Several authors [19][20][21][22][23][24][25][26] illustrate a dynamic explicit Arbitrary Lagrangian-Eulerian (ALE) based on FEM modeling using commercially available software's. FEM techniques such as adaptive meshing, explicit dynamics and fully coupled thermal-stress analysis are combined to simulate HSM with an orthogonal cutting model.…”

Section: Figmentioning

confidence: 99%

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

et al. 2020

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High-speed turning is an advanced and emerging machining technique that, in contrast to the conventional machining, allows the manufacture of the workpiece with high accuracy, efficiency and quality, with lower production costs and with a considerable reduction in the machining times. The cutting tools used for the conventional machining cannot be employed for high-speed machining due to a high temperature induced in machining and a lower tool life. Therefore, it is necessary to study the influence of high cutting speeds on the temperature distribution in different typologies of cutting tools, with the aim of evaluating their behavior. In this paper, a finite element method modeling approach with arbitrary Lagrangian-Eulerian fully coupled thermal-stress analysis is employed. The research presents the results of different cutting tools (two coated carbide tools and uncoated cermet) effects on average surface temperature fields on the cutting edge in the dry high-speed turning of AISI 1045 steel. The numerical experiments were designed based on different cutting tools like input parameters and different temperature field zones like dependent variables in the dry high-speed turning of AISI 1045 steel. The results indicate that the dry high-speed turning of AISI 1045 steel does not influence significantly the temperature field zones when P10, P15 or P25 inserts are used. Therefore, the use of a dry high-speed turning method, which reduces the amount of lubricant and increases productivity, may represent an alternative to turning to the extent here described.

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“…In recent years, the CEL formulation has been increasingly used to model various metal cutting processes such as orthogonal cutting of various workpiece materials, e.g. [11,[21][22][23], slot and shoulder milling of Al6061-T6 [24], intermittent longitudinal turning [25] and hard milling of AISI4140 [26]. The authors in [27] employed the CEL formulation to predict the drilling torque, burr formation and residual stresses in aerospace grade aluminium and titanium for various cutting parameters and the obtained results were benchmarked with an equivalent Lagrangian model.…”

Section: Introductionmentioning

confidence: 99%

Coupled Eulerian–Lagrangian simulation and experimental investigation of indexable drilling

Svensson

Andersson

Lassila

2022

Int J Adv Manuf Technol

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In many industries, indexable insert drills are used to cost effectively produce short holes. However, common problems such as chatter vibrations, premature tool wear and generation of long curly chips that cause poor chip evacuation make optimization of the drilling process challenging and time-consuming. Therefore, robust predictive models of indexable drilling processes are desirable to support the development towards improved tool designs, enhanced cutting processes and increased productivity. This paper presents 3D finite element simulations of indexable drilling of AISI4140 workpieces. The Coupled Eulerian–Lagrangian framework is employed, and the focus is to predict the drilling torque, thrust force, temperature distributions and chip geometries. To reduce the computational effort, the cutting process is modelled separately for the peripheral and the central inserts. The total thrust force and torque are predicted by superposing the predicted result for each insert. Experiments and simulations are conducted at a constant rotational velocity of 2400 rpm and feed rates of 0.13, 0.16 and 0.18 mm/rev. While the predicted torques are in excellent agreement, the thrust forces showed discrepancies of 12 - 20% to the experimental measured data. Effects of the friction modelling on the predicted torque and thrust force are outlined, and possible reasons for the thrust force discrepancies are discussed in the paper. Additionally, the simulations indicate that the tool, chip and the local workpiece temperature distributions are virtually unaffected by the feed rate.

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Investigation of mechanical and thermal loads in pcBN tooling during machining of Inconel 718

Cited by 31 publications

References 24 publications

Investigation of the Influence of Tool Rake Angles on Machining of Inconel 718

Investigation of the Influence of Tool Rake Angles on Machining of Inconel 718

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

Coupled Eulerian–Lagrangian simulation and experimental investigation of indexable drilling

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