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<p>During high-speed milling (HSM) of Inconel 718, intense thermomechanical stresses usually lead to substantial changes in surface and subsurface characteristics that affect the mechanical properties of the machined components. The objective of this research is to construct a predictable finite element (FE) model to investigate the grain size and microhardness during high-speed milling of Inconel 718. First, a finite element (FE)-based milling model was established and validated using experimental data on cutting forces, cutting temperature, chip morphology, achieving errors of 5–10%, 3–8%, and 5.2–14.3%. Second, the FE model had a user-defined subroutine that used the Zener–Holloman (Z-H) and Hall–Petch (H-P) equations to simulate dynamic recrystallization and predict grain size and microhardness of the machined surface. The simulation findings reveal that the grain size reduced with increasing the cutting speed and feed rate values. At a maximum cutting speed of 200&#xa0;m/min, and a feed rate of 0.14&#xa0;mm/z the grain size in the machined surface was reduced up to 9.11&#xa0;µm and 9.48&#xa0;µm for the TiAlN-coated milling insert and 8.69&#xa0;µm, and 8.49&#xa0;µm for the TiSiN-coated milling insert. Moreover, the microhardness on the milled surface improved as the cutting speed and feed rates were increased because of strong plastic deformation and thermal effects. Finally, the simulation results were confirmed by experimental data and microstructural characterization. A close agreement has been found between simulation and experimental outcomes. This research provides deep insights into microstructure evolution by demonstrating how optimized cutting parameters influence the surface quality and mechanical performance of machined components during high-speed milling operations.</p>

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Multiscale Simulation for Predicting grain Size and Microhardness in High-Speed Milling of Inconel 718

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Ghulam Mustafa,
  • Madhusudan Baghel,
  • Tianxiang Wang,
  • Song Zhang

摘要

During high-speed milling (HSM) of Inconel 718, intense thermomechanical stresses usually lead to substantial changes in surface and subsurface characteristics that affect the mechanical properties of the machined components. The objective of this research is to construct a predictable finite element (FE) model to investigate the grain size and microhardness during high-speed milling of Inconel 718. First, a finite element (FE)-based milling model was established and validated using experimental data on cutting forces, cutting temperature, chip morphology, achieving errors of 5–10%, 3–8%, and 5.2–14.3%. Second, the FE model had a user-defined subroutine that used the Zener–Holloman (Z-H) and Hall–Petch (H-P) equations to simulate dynamic recrystallization and predict grain size and microhardness of the machined surface. The simulation findings reveal that the grain size reduced with increasing the cutting speed and feed rate values. At a maximum cutting speed of 200 m/min, and a feed rate of 0.14 mm/z the grain size in the machined surface was reduced up to 9.11 µm and 9.48 µm for the TiAlN-coated milling insert and 8.69 µm, and 8.49 µm for the TiSiN-coated milling insert. Moreover, the microhardness on the milled surface improved as the cutting speed and feed rates were increased because of strong plastic deformation and thermal effects. Finally, the simulation results were confirmed by experimental data and microstructural characterization. A close agreement has been found between simulation and experimental outcomes. This research provides deep insights into microstructure evolution by demonstrating how optimized cutting parameters influence the surface quality and mechanical performance of machined components during high-speed milling operations.