Development of a 3D FE model for turning Inconel 718 superalloy as a precursor to modelling the high speed ball nose end milling process

Following a brief literature review, the paper details the development of a 3D finite element model for the turning of Inconel 718 using ABAQUS Explicit as a precursor for future end/ball end milling simulation. The model employs a Lagrangian formulation. Workpiece material property data were determined from experimental work on a Gleeble thermomechanical simulator using uniaxial compression testing, with temperatures and strain rates of up to https://www.w3.org/1998/Math/MathML" display="inline"> 850 ∘ C and 50/s respectively. Predicted and measured forces were within https://www.w3.org/1998/Math/MathML" display="inline"> 6 % for the cutting component, while feed forces were within https://www.w3.org/1998/Math/MathML" display="inline"> 29 % . Actual chip morphology determined from quick-stop experiments was segmented, whereas the predicted profile was continuous irrespective of the cutting speed. It is likely that the discrepancies were a result of oversimplification of the friction model, inadequacies in the algorithms describing material behaviour and lack of appropriate mechanical property data.