Scholarlink

<p>High-speed milling of Inconel 718 produces serrated chips that significantly affect surface characteristics and microstructural changes. This study examines serrated chip formation and surface microstructure through a combination of experimental and numerical methods. First, milling experiments were conducted at the cutting speeds of 100&#xa0;m/min, 150&#xa0;m/min, and 200&#xa0;m/min and feed rates of 0.1&#xa0;mm/z, 0.12&#xa0;mm/z, and 0.14&#xa0;mm/z using TiAlN-coated and TiSiN-coated inserts without any coolant to measure cutting forces, cutting temperature, and microstructural changes. Secondly, a basic 2D milling model using a numerically based Johnson–Cook constitutive material model was developed to understand the serrated chip formation. Thirdly, advanced characterization techniques, such as scanning electron microscopy and X-ray diffraction, were employed to investigate the microstructural and phase transformation analysis. Finally, the nanoindentation method was used to evaluate the hardness of the machined surface. Results reveal the effect of machining parameters on chip morphology, phase stability, and hardness, with experimental and simulated data showing strong correlation (errors of 3–9% for TiAlN and 2–8% for TiSiN), validating the numerical model. This work provides a robust framework for optimizing machining parameters and tool coatings for nickel-based superalloys.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

FEM-based numerical modeling of serrated chip formation in milling of Inconel 718

  • 期刊论文

  • 发表日期：

    2025年8月8日

查看全文
  • Ghulam Mustafa,
  • Tianxiang Wang,
  • Madhusudan Baghel,
  • Hongyu Liu,
  • Song Zhang

摘要

High-speed milling of Inconel 718 produces serrated chips that significantly affect surface characteristics and microstructural changes. This study examines serrated chip formation and surface microstructure through a combination of experimental and numerical methods. First, milling experiments were conducted at the cutting speeds of 100 m/min, 150 m/min, and 200 m/min and feed rates of 0.1 mm/z, 0.12 mm/z, and 0.14 mm/z using TiAlN-coated and TiSiN-coated inserts without any coolant to measure cutting forces, cutting temperature, and microstructural changes. Secondly, a basic 2D milling model using a numerically based Johnson–Cook constitutive material model was developed to understand the serrated chip formation. Thirdly, advanced characterization techniques, such as scanning electron microscopy and X-ray diffraction, were employed to investigate the microstructural and phase transformation analysis. Finally, the nanoindentation method was used to evaluate the hardness of the machined surface. Results reveal the effect of machining parameters on chip morphology, phase stability, and hardness, with experimental and simulated data showing strong correlation (errors of 3–9% for TiAlN and 2–8% for TiSiN), validating the numerical model. This work provides a robust framework for optimizing machining parameters and tool coatings for nickel-based superalloys.