Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718
Abstract
:1. Introduction
2. Finite Element Modelling of Orthogonal Cutting
2.1. Modelling Procedure
2.2. Constitutive Model of Inconel 718
2.3. Chip Separation Criterion
3. Results and Discussions
3.1. Geometrical Characteristics of Chips
3.2. Chip Deformation and Fracture under Different Cutting Speeds
3.3. Influence of JC Constitutive Parameters on Chip Shear Localization
3.4. Influence of JC Fracture Parameters on Chip Shear Localization
4. Conclusions
- The material constitutive parameters of initial yield stress A and hardening modulus B have positive relationships with the chip localized shear deformation, while the parameters n, C, and m all have the opposite influence on chip shear localization. The effects of parameters A and m on chip localized shear deformation are much more remarkable than the other three parameters. With the parameter A or m varying from a 20% decrease to a 20% increase, the chip shear localization sensitivity changes by 67.7% and 64.6%, respectively.
- When the JC fracture parameters of the workpiece material decline, the chip localized shear deformation is promoted while it is repressed when the material fracture parameters improve. The results demonstrate that the influences of parameters D1 and D2 on chip localized shear formation are more remarkable than the other three parameters. The chip shear localization sensitivity is larger than 70% when the parameter D1 or D2 is zero.
- The research demonstrates that an increase in the cutting speed promotes chip serration in Inconel 718 until the chip morphology becomes fragmented at the critical cutting speed of 7000 m/min. Serrated chips are generated by the mechanism of plastic deformation combined with ductile fracture, while fragmented chips are generated by brittle fracture due to embrittlement of the workpiece material under ultra-high cutting speeds.
- The limitation of this paper is that the influences of material mechanical properties on the chip formation process are researched only with JC material models and only the orthogonal cutting method has been focused on. The influence of other material models on the chip formation process and chip formation in more complex cutting modes will be researched in the future.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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A (MPa) | B (MPa) | n | C | m |
---|---|---|---|---|
1290 | 895 | 0.526 | 0.016 | 1.55 |
Density (kg/m3) | Elastic Modulus (GPa) | Poisson’s Ratio | Thermal Conductivity (W/m·K) | Specific Heat (J/kg·K) | Thermal Expansion Coefficient × 10−6 (/K) | Melting Temperature (K) |
---|---|---|---|---|---|---|
8240 | 200 (93 K) 181 (573 K) 160 (773 K) 141 (973 K) | 0.3 (293 K) 0.3 (473 K) 0.31 (691 K) 0.32 (873 K) | 10.63 (293 K) 14.7 (373 K) 17.8 (573 K) 19.6 (773 K) | 435 (293 K) 481.4 (573 K) 514.8 (773 K) 573.4 (973 K) | 11.8 (293 K–373 K) 13.0 (293 K–573 K) 14.1 (293 K–673 K) 14.8 (573 K–873 K) | 1573 |
D1 | D2 | D3 | D4 | D5 |
---|---|---|---|---|
0.04 | 0.75 | −1.45 | 0.04 | 0.89 |
Parameters | ↓ 20% | ↓ 10% | Original | ↑ 10% | ↑ 20% |
---|---|---|---|---|---|
A | 1032 | 1161 | 1290 | 1419 | 1548 |
B | 716 | 805.5 | 895 | 984.5 | 1074 |
n | 0.4208 | 0.4734 | 0.526 | 0.5786 | 0.6312 |
C | 0.0128 | 0.0144 | 0.016 | 0.0176 | 0.0192 |
m | 1.24 | 1.395 | 1.55 | 1.705 | 1.86 |
Di | ↓ 100% | ↓ 50% | Original | ↑ 50% | ↑ 100% |
---|---|---|---|---|---|
D1 | 0 | 0.02 | 0.04 | 0.06 | 0.08 |
D2 | 0 | 0.375 | 0.75 | 1.125 | 1.5 |
D3 | −2.9 | −2.175 | −1.45 | −0.725 | 0 |
D4 | 0 | 0.02 | 0.04 | 0.06 | 0.08 |
D5 | 0 | 0.445 | 0.89 | 1.335 | 1.78 |
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Wang, B.; Liu, Z.; Hou, X.; Zhao, J. Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718. Materials 2018, 11, 461. https://doi.org/10.3390/ma11040461
Wang B, Liu Z, Hou X, Zhao J. Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718. Materials. 2018; 11(4):461. https://doi.org/10.3390/ma11040461
Chicago/Turabian StyleWang, Bing, Zhanqiang Liu, Xin Hou, and Jinfu Zhao. 2018. "Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718" Materials 11, no. 4: 461. https://doi.org/10.3390/ma11040461