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Materials Today: Proceedings 18 (2019) 4531–4636 www.materialstoday.com/proceedings

ICMPC-2019

Heat assisted machining of Inconel 718 Alloy using Abaqus/Explicit

A Kiran Kumara*, P Venkataramaiahb
a
Research scholar,Department of mechanical engineering, S.V.University,Tirupati,517502, India
b
Professor, Department of mechanical engineering, S.V.University,Tirupati,517502, India

Abstract

Nickel-based alloys have superior properties like high strength, low thermal conductivity and extreme fatigue strength however
these properties make machining very difficult. Since Inconel 718 alloy has extensive applications in the field of aerospace, we
need to find the best ways to improve its machinability. Heat assisted machining is one technique which makes machining easier
because it reduces the shear strength of the work piece when compare to machining at room temperature. In the present paper,
Abaqus/explicit software is used to study the influence of pre heating temperature on surface roughness and cutting forces during
machining of Inconel 718 alloy using coated and uncoated tools. Finally the results are compared at room temperature and
preheating conditions.

© 2019 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019

Keywords: Heat assisted machining, Abaqus/Explicit, Johnson Cook Model, Surface roughness, Inconel 718

1. Introduction

Nickel based super have a key role in aerospace industry due to its exceptional mechanical, chemical and thermal
properties at elevated temperatures. However these properties leads to difficult to machine and the surface quality of
a machined component can be affected if proper machining conditions are not taken. In past studies, many
researchers carried out the machining of difficult to cut materials using finite element simulation. The effect of nose
radius on temperature distribution in the tool is analyzed and noticed increase of cutting force and thrust force with
increase of nose radius at both room and pre heating conditions [1].

* Corresponding author.
E-mail address: kirankumar.abbili@gitam.edu

2214-7853© 2019 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
4532 A K. Kumar et al./ Materials Today: Proceedings 18 (2019) 4531–4636

Nomenclature

A - Yield stress (MPa)

B - Strain hardening parameter (MPa)
n - Strain hardening exponent
C - Strain rate sensitivity parameter
m -Temperature exponent
εp - Plastic strain
.
 *  ( p * /  0 ) is dimensionless strain rate
T*m = (T-T0) / (Tm –T0); T, T0 and Tm being the working temperature,
room temperature and melting temperature respectively.
εf = fracture strain
D1 to D5 are coefficients of Johnson-Cook material shear failure
initiation criterion
σ*= σm / σeq is the stress
σeq = equivalent stress
σm =mean stress

The effect of different edge roundness on residual stresses in machining of AISI304 steel has been studied using
FE model [2]. Surface roughness is predicted in terms of effective feed rate of the cutting force components during
the face milling operation of titanium alloy [3]. Prediction of temperature and its measurement during the machining
of Ni-based super alloys has been carried out as it is critical factor to control the machining process, avoiding the
work piece damage [4]. It is recommended that J-C model is still the best model for conducting the simulation of
machining process because of its robustness and simple to apply using FEM [5]. Generation and distribution of
temperature during chip formation has been studied using Abaqus software and also analyzed the stresses in
machining [6]. Selection of suitable J-C model parameters will play an important role in order to get the best fit
between predicted and measured results [7, 12, and 13]. Chip morphology in orthogonal machining using numerical
model is compared with experimental studies to validate the results [8]. The residual stress present in the machined
component using different materials through simulation has been reported [9, 10]. The influence of nose radius in
chip formation and stress distribution is studied using finite element simulation [11]. In past, most of the works in
machining simulations focused on effect of different parameters like speed, feed, depth of cut and tool geometry on
cutting forces and temperature distribution and residual stresses but very few works were found in heat assisted
machining using FEM simulation . In this paper, the objective is to study the machinability of Inconel 718 alloy
using Abaqus/Explicit software and also the influence of room temperature and preheating temperature conditions
on surface roughness by keeping speed, feed and depth of cut constant.

2. Finite Element Modeling

3D model of work piece and cutting tool were created and Johnson-Cook Model (Eq.1) has been deployed to the
model which can relate the material behavior at high temperatures, high strains and high strain rates. Fig.1 (a) and
Fig.1 (b) show the 3D and FEM model of work piece and cutting tool. Johnson-Cook failure model (Eq.2) is
employed to define the chip removal in simulation process. The J-C model parameters are very much appropriate in
dynamic simulation applications.
 A K. Kumar et al./ Materials Today: Proceedings 18 (2019) 4531–4636 4533

 .


 eq  A  B p n
 .*

1  C ln( )  1  T *m
 
 (1)

 

. (2)
 f  [ D1  D2 exp( D3 * )][1  D4 ln( p * )[1  D5T * ]

Fig.1. (a) Solid Model of work piece and tool Fig1. (b) FEM Model of work piece and tool

J-C model parameter values for Inconel 718 alloy considered are listed in Table 1. The element type (C3D8RT) is
selected which is suitable for the study of both the mechanical and thermal aspects of work piece in machining
simulation. The properties of Inconel 718 alloy and cutting tools (coated and uncoated) and the tool geometry are
listed in Table 2 and 3.

Table 1: J-C model parameters of Inconel 718 alloy Table 2: Geometry of cutting Tool

A(MPa) B(MPa) n m C Rake angle, α Clearance angle Nose radius(mm)

0 0
980 1370 0.164 1.03 0.020 6 6 0.8
D1 D2 D3 D4 D5
0.11 0.75 -1.45 0.04 0.89

Table 3: Properties of Work piece and Tool

S. No Parameter Inconel 718 WC TiN Coated

1 Density(kg/m3) 8195 15700 5220

2 Young’s Modulus(Gpa) 200 705 600
3 Poisson ratio 0.3 0.23 0.25
4 Thermal 11.4 24 19
conductivity(W/m0C)
5 Specific heat(J/Kg/0C) 430 178 -

The interaction of work piece and tool during the chip formation process plays a key role in determining the
surface finish [14]. The coefficient of friction of 0.6 is chosen and the interaction between tool and work piece is
considered as general contact. The boundary conditions of work piece and tool are shown in Figure 2 as bottom
4534 A K. Kumar et al./ Materials Today: Proceedings 18 (2019) 4531–4636

portion of the work piece is fixed and the tool has given degree of freedom along x-direction. The cutting parameters
used in simulation of hot turning of Inconel 718 alloy is illustrated in the Table 4.
Among all the parameters speed, feed and depth of cut are kept constant in order to the study the influence of
preheating temperature and also the type of tool on surface roughness and cutting force.

Fig.2: Boundary conditions of work piece and tool

Table 4: Machining parameters

S.No Tool Speed Feed DOC Temp(oC)

(m/min) (mm/rev) (mm)
1 Uncoated 30
2 Uncoated 100 0.11 0.2 300
3 Uncoated 600
4 Coated 30
5 Coated 300
6 Coated 600

3. Results and Discussion

Simulations performed in Abaqus/Explicit software at different heating conditions using coated and uncoated
tools in order to study the influence on surface roughness and cutting forces. Cutting force plots of the simulations
are shown in the Figure 3(a & b). Surface roughness is estimated based on the feed force, as the surface roughness is
proportional to the feed force [3]. The cutting forces obtained in these simulations are listed in the Table 5. Due to

Figure 3(a): Cutting force plot with uncoated tool Figure 3(b): Cutting force plot with coated tool
 A K. Kumar et al./ Materials Today: Proceedings 18 (2019) 4531–4636 4535

Table 5: Results Table

S.No Tool Speed Feed DOC Temp(oC Cutting Force(N) Feed Force(N) Radial
) Force(N
(m/min) (mm/rev) (mm)
)
1 Uncoated 30 195 136.7 144.5
2 Uncoated 300 137.3 93.4 160.1
3 Uncoated 100 0.11 0.2 600 132 48.53 98.8
4 Coated 30 175 56.63 167.
5 Coated 300 147.5 91 131.3
6 Coated 600 137.3 85.8 86.6

pre heating, the work piece gets soften which reduces the shear strength and because of this it is observed that the
cutting forces are reduced at 600 0 C compared to room temperature. Similar trend is noticed during the use of
uncoated and coated tool. The cutting force variation with respect to pre heating temperature and cutting tools are
plotted in Fig. 4 (a &b). The influence on surface roughness can be represented in terms of feed force which shows
the similar trend to surface roughness. Hence it can be observed that the surface roughness is also reducing with
increase in pre heating temperature. It is also observed that cutting forces got reduced during the coated tool case.

250
200
150 Cutting Force(N)
100 Feed Force(N)
50
Radial Force(N)
0
30 Deg. C 300 Deg.C 600 Deg.C

Fig 4a: Variation of cutting Force with uncoated tool at different temperatures

200

150
Cutting Force(N)
100
Feed Force(N)
50
Radial Force(N)
0
30(Deg. C) 300(Deg.C) 600(Deg. C)

Fig 4b Variation of cutting Force with coated tool at different temperatures:

4536 A K. Kumar et al./ Materials Today: Proceedings 18 (2019) 4531–4636

4. Conclusions

From the simulation s of heat assisted machining of Inconel 718 alloy the following conclusions are drawn.

1. The machining of Inconel 718 alloy at room temperature (300C), 3000C and 6000C were simulated in
Abaqus/Explicit by considering uncoated and coated tool.
2. Cutting forces got reduced at 6000C pre heating temperature compared to room temperature condition.
3. Surface roughness variation is predicted in terms of Feed force which is also reduced at pre heating
temperature compared to room temperature condition.
4. Machining with coated tool is resulting less cutting forces compared to uncoated tool at different pre heating
temperatures.
5. Hence it is clear that the machinability of hard to cut materials like Inconel 718 alloy can be improved with
aid of pre heating during machining.

5. References

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analysis. Engineering Science and Technology, an International Journal 20 (2017) 687–693
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[3] Moaz H. Ali, Basim A. Khidhir, M.N.M. Ansari, Bashir Mohamed, 2013, FEM to predict the effect of feed rate on surface roughness with
cutting force during face milling of titanium alloy. HBRC Journal (2013) 9,263-269
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