Abstract
Since the 1960s, the Inconel Alloy 718 has been a standard nickel-based superalloy due to its high strength, balanced mechanical properties, and strong corrosion resistance at relatively low costs and has been widely used in critical aircraft engine components. With the aim of improving productivity and product quality by implementing advanced tools and new process designs, models such as the FE model are utilized to predict the machining performance such as the cutting forces, the tool life, and the surface integrity. In the research area of FEM chip formation simulation, the influence of flank wear on predictions has not been investigated, especially not on the underestimation of the cutting normal force. In this paper, a 2D FEM chip formation model with the coupled Eulerian-Lagrangian (CEL) method has been built to predict cutting forces as well as other material loadings (Brinksmeier et al. Procedia CIRP 13:429–434, 2014; Buchkremer and Klocke Wear 376-377:1156–1163, 2017) in the machining of Direct Aged 718. In order to validate the performance of the FE model, fundamental investigations have been performed in orthogonal cutting with different cutting parameters. Two kinds of cemented carbide cutting tools with different cobalt contents have been applied to achieve different tool wear behaviors. Moreover, the underestimation of the cutting normal force by FEM chip formation simulation has been investigated and solved in consideration of the flank wear. The introduced FE-modeling approach shows precise predictions in terms of the cutting forces and the chip formation.
Similar content being viewed by others
References
Abaqus V (2014) 6.14 documentation. Dassault Systemes Simulia Corporation 651
Agmell M, Bushlya V, Laakso SVA, Ahadi A, Ståhl JE (2018) Development of a simulation model to study tool loads in pcbn when machining aisi 316l. Int J Adv Manuf Technol 96(5-8):2853–2865. https://doi.org/10.1007/s00170-018-1673-y
Arrazola PJ, Aristimuno P, Soler D, Childs T (2015) Metal cutting experiments and modelling for improved determination of chip/tool contact temperature by infrared thermography. CIRP Ann 64(1):57–60. https://doi.org/10.1016/j.cirp.2015.04.061
Arrazola PJ, Özel T (2010) Investigations on the effects of friction modeling in finite element simulation of machining. Int J Mech Sci 52(1):31–42. https://doi.org/10.1016/j.ijmecsci.2009.10.001
Arrazola PJ, Özel T, Umbrello D, Davies M, Jawahir IS (2013) Recent advances in modelling of metal machining processes. CIRP Ann Manuf Technol 62(2):695–718. https://doi.org/10.1016/j.cirp.2013.05.006
Biermann D, Hollmann F (2018) Thermal effects in complex machining processes: Final report of the DFG priority programme. In: Lecture Notes in Production Engineering. Springer International Publishing and Imprint, vol 1480. Springer, Cham
Biermann D, Oezkaya E (2017) CFD simulation for internal coolant channel design of tapping tools to reduce tool wear. CIRP Ann 66(1):109–112. https://doi.org/10.1016/j.cirp.2017.04.024
Binder M (2017) Mechanismenbasierte Verschleißsimulation zur integrierten Werkzeug- und Prozessauslegung. Dissertation RWTH Aachen and IIF - Institut für Industriekommunikation und Fachmedien GmbH
Brinksmeier E, Klocke F, Lucca DA, Sölter J., Meyer D (2014) Process signatures – a new approach to solve the inverse surface integrity problem in machining processes. Procedia CIRP 13:429–434. https://doi.org/10.1016/j.procir.2014.04.073
Buchkremer S, Klocke F (2017) Compilation of a thermodynamics based process signature for the formation of residual surface stresses in metal cutting. Wear 376-377:1156–1163. https://doi.org/10.1016/j.wear.2016.11.013
Calamaz M, Coupard D, Girot F (2008) A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V. Int J Mach Tools Manuf 48(3-4):275–288. https://doi.org/10.1016/j.ijmachtools.2007.10.014
Chen G, Ren C, Yang X, Jin X, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model. Int J Adv Manuf Technol 56(9-12):1027–1038. https://doi.org/10.1007/s00170-011-3233-6
Courbon C, Mabrouki T, Rech J, Mazuyer D, D’Eramo E (2013) On the existence of a thermal contact resistance at the tool-chip interface in dry cutting of AISI 1045: Formation mechanisms and influence on the cutting process. Appl Therm Eng 50(1):1311–1325. https://doi.org/10.1016/j.applthermaleng.2012.06.047
Courbon C, Sajn V, Kramar D, Rech J, Kosel F, Kopac J (2011) Investigation of machining performance in high pressure jet assisted turning of Inconel 718: A numerical model. J Mater Process Technol 211(11):1834–1851. https://doi.org/10.1016/j.jmatprotec.2011.06.006
Devillez A, Schneider F, Dominiak S, Dudzinski D, Larrouquere D (2007) Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools. Wear 262(7-8):931–942. https://doi.org/10.1016/j.wear.2006.10.009
Erice B, Gálvez F (2014) A coupled elastoplastic-damage constitutive model with lode angle dependent failure criterion. Int J Solids Struct 51(1):93–110. https://doi.org/10.1016/j.ijsolstr.2013.09.015
Hoppe S (2003) Experimental and numerical analysis of chip formation in metal cutting. Dissertation. RWTH Aachen, Aachen
Johnson GR, Cook WH (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Procedings of the 7th int. symposium on ballistics, the hague, The Netherlands, pp 541–547
Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48. https://doi.org/10.1016/0013-7944(85)90052-9
Klocke F (2011) Manufacturing process. RWTH edition. Springer, Berlin
Klocke F, Döbbeler B, Peng B, Lakner T (2017) FE-simulation of the cutting process under consideration of cutting fluid. Procedia CIRP 58:341–346. https://doi.org/10.1016/j.procir.2017.03.235
Klocke F, Döbbeler B, Peng B, Schneider S (2018) Tool-based inverse determination of material model of direct aged alloy 718 for fem cutting simulation. Procedia CIRP 77:54–57. https://doi.org/10.1016/j.procir.2018.08.211
Klocke F, Gierlings S, Vogtel P, Veselovac D, Lung D (2012) Impact of cutting speed and material on surface quality in broaching of Nickel-Based Alloys. Ninth international conference on High Speed Machining HSM, San Sebastian, Spain, pp 978–984
Krueger DD (1989) The development of Direct Age 718 for gas turbine engine disk applications. Superalloy 718: Metallurgy and Applications 1989:279–296
Laakso SV, Agmell M, Ståhl JE (2018) The mystery of missing feed force — the effect of friction models, flank wear and ploughing on feed force in metal cutting simulations. J Manuf Process 33:268–277. https://doi.org/10.1016/j.jmapro.2018.05.024
Lane BM, Dow TA, Scattergood R (2013) Thermo-chemical wear model and worn tool shapes for single-crystal diamond tools cutting steel. Wear 300(1-2):216–224. https://doi.org/10.1016/j.wear.2013.02.012
Lorentzon J, Järvstråt N (2008) Modelling tool wear in cemented- carbide machining alloy 718. Int J Mach Tools Manuf 48(10): 1072–1080. https://doi.org/10.1016/j.ijmachtools.2008.03.001
Oberwinkler B (2016) Integrated process modeling for the mechanical properties optimization of Direct Aged Alloy 718. https://doi.org/10.1002/9781119075646.ch55
Oxley PLB (1963) Rate of strain effect in metal cutting. Journal of Engineering for Industry 85(4):335. https://doi.org/10.1115/1.3669884
Özel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf 46(5):518–530. https://doi.org/10.1016/j.ijmachtools.2005.07.001
Pirso J, Letunovitš S, Viljus M (2004) Friction and wear behaviour of cemented carbides. Wear 257(3-4):257–265. https://doi.org/10.1016/j.wear.2003.12.014
Puls H, Klocke F, Lung D (2014) Experimental investigation on friction under metal cutting conditions. Wear 310(1-2):63–71. https://doi.org/10.1016/j.wear.2013.12.020
Puls H, Klocke F, Veselovac D (2015// 2016) FEM-based prediction of heat partition in dry metal cutting of AISI 1045. Int J Adv Manuf Technol 86(1-4):737–745. https://doi.org/10.1007/s00170-015-8190-z
Rech J, Arrazola PJ, Claudin C, Courbon C, Pusavec F, Kopac J (2013) Characterisation of friction and heat partition coefficients at the tool-work material interface in cutting. CIRP Ann Manuf Technol 62(1):79–82. https://doi.org/10.1016/j.cirp.2013.03.099
Saito H, Iwabuchi A, Shimizu T (2006) Effects of Co content and WC grain size on wear of WC cemented carbide. Wear 261(2):126–132. https://doi.org/10.1016/j.wear.2005.09.034
Seimann M, Peng B, Fischersworring-Bunk A, Rauch S, Klocke F, Döbbeler B (2018) Model-based analysis in finish broaching of Inconel 718. Int J Adv Manuf Technol 97(9-12):3751–3760. https://doi.org/10.1007/s00170-018-2221-5
Usui E, Shirikashi ST, Kitagawa T (1984) Analytical prediction of cutting tool wear. Wear 1984 // 100(1-3):129–151. https://doi.org/10.1016/0043-1648(84)90010-3
Vogtel P, Klocke F, Puls H, Buchkremer S, Lung D (2013) Modelling of process forces in broaching Inconel 718. Procedia CIRP 8:409–414
Wan M, Ye XY, Wen DY, Zhang WH (2019) Modeling of machining-induced residual stresses. J Mater Sci 54(1):1–35. https://doi.org/10.1007/s10853-018-2808-0
Yen YC, Söhner J, Lilly B, Altan T (2004) Estimation of tool wear in orthogonal cutting using the finite element analysis. J Mater Process Technol 146(1):82–91. https://doi.org/10.1016/S0924-0136(03)00847-1
Zemzemi F, Rech J, Salem WB, Dogui A, Kapsa P (2014) Identification of friction and heat partition model at the tool-chip-workpiece interfaces in dry cutting of an Inconel 718 alloy with CBN and coated carbide tools. Advances in Manufacturing Science and Technology 38(1). https://doi.org/10.2478/amst-2014-0001
Zhang Y, Outeiro JC, Mabrouki T (2015) On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4V using three types of numerical models of orthogonal cutting. Procedia CIRP 31:112–117. https://doi.org/10.1016/j.procir.2015.03.052
Funding
The authors would like to thank the German Research Foundation (DFG) for the funding of the depicted research within the project ”Modelling of broaching processes by multi-scale discretization” (KL 500/159-1).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Peng, B., Bergs, T., Klocke, F. et al. An advanced FE-modeling approach to improve the prediction in machining difficult-to-cut material. Int J Adv Manuf Technol 103, 2183–2196 (2019). https://doi.org/10.1007/s00170-019-03456-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03456-0