Mechanism of Chip Formation in High-Speed Turning of Inconel 718

Pawade, Raju S.; Joshi, Suhas S.

doi:10.1080/10910344.2011.557974

Cited by 73 publications

(25 citation statements)

References 18 publications

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“…The results show that the increase in cutting speed leads to an increase of chip serration frequency. Similar trends between the cutting speed and chip morphology, including the chip serration degree and serration frequency, have also been found in the publications of other researchers [ 28 , 29 ]. However, when the chip morphology evolves to a fragmented one at V = 7000 m/min, the parameter f is no longer applicable to characterize the chip geometrical features.…”

Section: Resultssupporting

confidence: 85%

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

2018

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The paper aims to investigate the influences of material constitutive and fracture parameters in addition to cutting speed on chip formation during high-speed cutting of Inconel 718. Finite element analyses for chip formation are conducted with Johnson–Cook constitutive and fracture models. Meanwhile, experiments of high-speed orthogonal cutting are performed to verify the simulation results with cutting speeds ranging from 50 m/min to 7000 m/min. The research indicates that the chip morphology transforms from serrated to fragmented at the cutting speed of 7000 m/min due to embrittlement of the workpiece material under ultra-high cutting speeds. The parameter of shear localization sensitivity is put forward to describe the influences of material mechanical properties on serrated chip formation. The results demonstrate that the effects of initial yield stress and thermal softening coefficient on chip shear localization are much more remarkable than the other constitutive parameters. For the material fracture parameters, the effects of initial fracture strain and exponential factor of stress state on chip shear localization are more much prominent. This paper provides guidance for controlling chip formation through the adjustment of material mechanical properties and the selection of appropriate cutting parameters.

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Section: Resultssupporting

confidence: 85%

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

2018

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“…In the machining of Inconel 718, the critical machining speed for chip segmentation is found to be around 50 m/min, above which the saw tooth chip would be formed. As reported by Pawade and Joshi [55], segmented chip formation in machining of Inconel 718 would increase the surface roughness value. Further study shows that, the localize shear band in the chip, which elongated grain size occurs, also contributes the segmented chip.…”

Section: Nickel-based Alloysmentioning

confidence: 61%

Material microstructure affected machining: a review

2017

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-The machining induced material microstructure evolution path is determined from the temperature and mechanical loading history. Inversely, the machining forces and machined part surface integrity are dependent on the material microstructure attributes. Most of the previous research work with a microstructure consideration in machining stays largely on the experimental observation stage. A comprehensive thermal-mechanical-microstructure coupled machining process modeling framework is still missing. This paper reviews the recent research work on the material microstructure evolution in the context of machining components. The material microstructure property change on the workpiece material in the machining process are analyzed. The effects of material microstructure evolution on workpiece mechanical properties and surface integrity are investigated. It is concluded that a physical based material microstructure affected machining model is needed for the machining process optimization.

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“…In practice, the saturation of the shear force close to zero value describes the saw-tooth-like chip segmentation (as represented in our high speed camera measurements in Fig 4). The chaotic behaviour predicted by the model has already been presented in [15]. Parameter…”

Section: Model Of Chip Formationmentioning

confidence: 77%

Stability of turning processes for periodic chip formation

Gyebrószki

Bachrathy

Csernák³

et al. 2018

Adv. Manuf.

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The prediction of chatter vibration is influenced by many known complex phenomena, still the predictions can be uncertain. We present a new effect which can significantly change the stability properties of cutting processes. It is shown that the microscopic environment of the chip formation can have large effect on the macroscopic properties. In this work, a combined model of the surface regeneration effect and the chip formation is used to predict the stability in turning processes. In the chip segmentation sub-model, the primary shear zone is described with the corresponding material model along layers together with the thermodynamical behaviour. The surface regeneration is modelled by the timedelayed differential equation. Numerical simulations show, that the time scale of chip segmentation model is significantly smaller than the time scale of the turning process, therefore, averaging methods can be used. Due to the non-linear effects, the chip segmentation can decrease the average shear force leading to decreased cutting coefficients. The proper linearization of the equation of motion leads to an improved description of the cutting coefficients. It is shown that the chip segmentation may significantly increase the stable domains in the stability charts, furthermore, with selecting proper parameters, unbounded stability domains could be reached. Keywords chip formation • chatter • turning • delay The research leading to these results has received funding from the European Research Council under the European Union's Seventh Framework Programme (FP7/2007-2013) ERC Advanced grant agreement №340889.

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Mechanism of Chip Formation in High-Speed Turning of Inconel 718

Cited by 73 publications

References 18 publications

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

Material microstructure affected machining: a review

Stability of turning processes for periodic chip formation

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