Numerical contribution to segmented chip effect on residual stress distribution in orthogonal cutting of Inconel718

Segmented chip morphology has a significant influence on distribution of residual stress and surface topography on machined surface in machining difficult-to-cut materials. In this paper, Coupled Eulerian and Lagrangian (CEL) model is employed to investigate the effect of segmented chip on surface integrity (residual stress distribution and surface topography) in orthogonal machining of Inconel718 with uncoated carbide inserts. A mesh sensitivity study of chip morphology and residual stress distribution is performed by developing the following three different grid resolutions: coarse (mesh size 35 μm), medium (10 μm) and fine (5 μm). Comparing with the experimental results, it is clear that the numerical model presents reasonable results, including the chip morphology, temperature distribution, cutting forces, residual stress profile and surface fluctuation period. As for the generated surface integrity, a waved surface and cyclic residual stress distribution are found with the segmented chip due to the periodical mechanical and thermal loadings acting on the machined surface. Furthermore, the formation of single chip segment is investigated in-depth to explain the residual stress distribution generation.