This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiCw + Al2O3, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiCw + Al2O3 tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiCw + Al2O3 emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.

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Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617

  • Chandramani Upadhyay,
  • Sumit Singh Rajput,
  • Vivek Kumar Sahu,
  • Soumya Gangopadhyay,
  • Susanta Kumar Sahoo

摘要

This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiCw + Al2O3, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiCw + Al2O3 tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiCw + Al2O3 emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.