Numerical analysis of chip geometry on hot machining of nickel base alloy

Abstract

In this present study, the relation between the heating temperature and chip geometry has been studied using DEFORM software. Due to low thermal conductivity, the Inconel 718 forms serrated chip because of shear localization at the primary shear zone. The simulation has carried out in both room and two heating temperatures (300 and 600 °C), with three cutting speeds, constant feed rate, and depth of cut. Chip geometry in terms of degree of segmentation, serration frequency, equivalent chip thickness, shear plane length, and chip pitch has been predicted. Cutting force and thrust force have also been recorded at steady-state cutting conditions. The predicated results have been compared with the previous experimental study, and good correlation has been obtained.