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

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Abstract

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.

Detaljer

Författare
Enheter & grupper
Externa organisationer
  • University of Nottingham
Forskningsområden

Ämnesklassifikation (UKÄ) – OBLIGATORISK

  • Tribologi

Nyckelord

Originalspråkengelska
Sidor (från-till)993–1005
TidskriftInternational Journal of Advanced Manufacturing Technology
Volym109
StatusPublished - 2020
PublikationskategoriForskning
Peer review utfördJa