A simulation approach for estimating flank wear and material removal rate in turning of Inconel 718Simulation Modelling Practice and Theory

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Authors
Rajiv Kumar Yadav, Kumar Abhishek, Siba Sankar Mahapatra
Year
2015
DOI
10.1016/j.simpat.2014.12.004
Subject
Hardware and Architecture / Software / Modelling and Simulation

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Text

Keywords:

Flank wear

Material removal rate

The machining simulation is carried out to predict the flank wear and material removal lloys urning of Inconel ion [1–12]. ave been d (FEM) ap [16–32]. In fact, finite element (FE) machining models plays an important role in understanding chip formation a wear analysis without resorting to costly and time consuming experimental approach. Generally, two dime orthogonal plane strain assumption or arbitrary damage criterion or remeshing techniques for chip formation are used in http://dx.doi.org/10.1016/j.simpat.2014.12.004 1569-190X/ 2014 Elsevier B.V. All rights reserved. ⇑ Corresponding author.

E-mail addresses: rajiv.nitrkl@gmail.com (R.K. Yadav), krabhishek1987@gmail.com (K. Abhishek), mahapatrass2003@gmail.com (S.S. Mahapatra).

Simulation Modelling Practice and Theory 52 (2015) 1–14

Contents lists available at ScienceDirect

Simulation Modelling Practice and Theory journal homepage: www.elsevier .com/ locate/s impatturning operations is most commonly performed to modify shape, dimension, and surface of a work piece. T 718 is indeed a challenging task due to excessive tool wear resulting in poor surface finish and heat generat low machinability, turning of Inconel 718 is a time and cost consuming effort. Therefore, many studies h towards simulation of turning operation of Inconel 718 using three-dimensional finite element methodDue to irected proach nd tool nsionaljet engines and gas turbines due to its high yield strength, excellent fatigue resistance and good corrosion endurance in severe conditions. Out of commercially available nickel base super-alloys, Inconel 718 is mostly used in aircraft gas turbines, reciprocating engines, space vehicles, nuclear power plants, chemical and petrochemical industries and heat exchangers. The mechanical components are mainly produced to required shape using different machining operations. Therefore, it becomes essential to understand the material removal process in metal cutting and judicious selection of tool material to maintain desired dimensional accuracy and surface integrity of the finished product. Out of many conventional machining methods,Finite element analysis

Analysis of variance

Wear model 1. Introduction

Now-a-days, nickel-based super arate (MRR). Flank wear is calculated using Usui’s wear model in the simulation model.

The results from simulation model are compared with experimental data generated by the use of Taguchi’s L16 orthogonal array for reducing the experimental runs. Analysis of variance (ANOVA) is performed to identify the most influencing variables for both the performance characteristics. It is found that simulation results are in good agreement with experimental results. A valid simulation models helps the tool engineers to gather relevant process related information without resorting to costly and time consuming experimentation.  2014 Elsevier B.V. All rights reserved. are extensively used in aerospace industry particularly in making components forA simulation approach for estimating flank wear and material removal rate in turning of Inconel 718

Rajiv Kumar Yadav ⇑, Kumar Abhishek, Siba Sankar Mahapatra

Department of Mechanical Engineering, National Institute of Technology, Rourkela 769008, India a r t i c l e i n f o

Article history:

Received 7 February 2014

Received in revised form 27 November 2014

Accepted 9 December 2014 a b s t r a c t

The present work attempts to study the effect of important machining variables on performance characteristics such as material removal rate and tool wear in turning of Inconel 718 using chemical vapour deposition (CVD) coated tungsten carbide (WC) tool. A three dimensional machining model using Lagrangian approach has been developed using DEFORM 3D. with multilayer CVD (chemical vapour deposition) coatings in dry turning of low carbon alloy steel (AISI/SAE-4140) over a 2 R.K. Yadav et al. / Simulation Modelling Practice and Theory 52 (2015) 1–14wide range of cutting speeds (between 200 and 879 m/min). The study reveals that coating layouts and cutting tool edge geometry significantly affect heat distribution in the cutting tool.

Zhao et al. [13] have examined the effect of internal cooling on the flank wear of cutting tool in orthogonal cutting. The study has also presented a flank wear model for a cutting tool based on wear models considering the normal stress and thermal softening. Arsecularatne et al. [14] have studied wear mechanisms of cutting tools made of tungsten-carbide (WC), polycrystalline cubic boron nitride (PCBN) and polycrystalline diamond (PCD) considering tool life and tool tip temperature. The study reveals that dominant tool wear mechanism for WC is diffusion wear whereas chemical wear for PCBN. Usui et al. [15] have developed an analytical model for crater and flank wear of tungsten carbide tool insert. Wear characteristics equation is first derived theoretically and verified experimentally.

Zebala and Slodki [16] have applied finite element modelling (FEM) to analyse the effect of chip breakers during turning of Inconel 718. Uhlmann et al. [17] have studied the formation of chips during high speed turning of Inconel 718 using different software such as DEFORM and ABAQUS. Vaz et al. [18] have explained the complex physical phenomenon involved in chip formation using numerical modelling. Lorentzon and Jarvstrat [19] have developed an empirical model through a finite element simulation to predict tool wear in machining of Inconel 718. It has been shown that advanced friction model is necessary than Coulomb friction for accurate prediction of wear. Lorentzon et al. [20] have examined the effect of differentFE modelling needing more computational efforts. However, three dimensional computational models can be adopted to study the mechanism of material removal process together with its influence on the machined part and wear behaviour on the cutting tool for analyzing physical phenomenon in materials undergoing large elastic–plastic deformation.