Skip to main content
SpringerLink
Log in

A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In metal cutting process, size effects and edge effects have a significant influence on cutting forces and therefore on the machining performance. This paper facilitates those behaviors with different cutting tool geometry, i.e., round edge and chamfered edge, using analytical cutting force prediction models when turning Inconel 718 with round cutting inserts. Analytical methods used for different edge preparation are developed with the consideration of size effects and edge effects. Then, an attempt is made to analyze the cutting investigations of the influence of size effects and edge features. The cutting forces and edge forces are estimated with the modified Johnson–Cook constitute model considering the size effects and edge effects. Rounded edge coefficients and chamfered edge coefficients estimated with different analytical methods are used in calculating edge forces for rounded edged tools and chamfered edged tools, respectively. Simulations with finite element model (FEM) and cutting experiments are used to verify the proposed model. Finally, the detailed influences of size effects, edge geometries, and feed rate on the cutting forces are studied based on the proposed model and FEM simulations.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Abbreviations

R :

Radius of round insert

f, f c :

Feed rate, feed rate on rake face plane

h j c :

Uncut chip thickness on the rake face plane

ϕ st ϕ mid ϕ ex :

Separation immersion angles

ϕ s, ϕ s j :

Immersion angle, immersion angle of element j

α n :

Normal rake angle

F x j F y j F z j :

Force components on element j in cutting in Caretesian coordinate system

F t j F r j F f j :

Force components on element j in cutting velocity, tangential and radial direction

a p :

Cutting depth

d j c :

Width of uncut chip zone of element j

Doc :

Depth of cut in simulations

λ s 0 λ s j :

Initial inclination angle, inclination angle of element j

K tc j K rc j K fc j :

Cutting coefficients

K te j K re j K fe j :

Edge coefficients

τ s j :

Shear flow stress of element j

η c j :

Local chip flow angle of element j

β n j :

Friction angle of element j

r :

Edge radius

θ :

Chamfer angle

l :

Chamfer length

θ 0 :

Stagnation point angle

γ, \( \dot{\gamma} \) :

Shear strain and shear strain rate

\( {\dot{\gamma}}_0 \) \( {\dot{\gamma}}_m \) :

Reference plastic strain rate and maximum strain rate

T, T r, T m :

Chip instantaneous temperature, room temperature and melting temperature

ϕ n j :

Normal shear angle of element j

V j c :

Chip flow velocity of element j

f j :

Mean friction coefficient

f 0, p :

Constants of friction coefficient

ρ c μ :

Density of the material, specific heat capacity, Taylor-Quinney coefficient

A, B, C, m, n :

Coefficients of the Johnson–Cook model

b g :

Magnitude of the Burgers vector

M \( \overline{r} \) G :

Taylor factor, Nye factor, shear modulus

References

  1. Zhang X, Yu T, Wang W (2017) Cutting forces modeling for micro flat end milling by considering tool run-out and bottom edge cutting effect. Proc Inst Mech Eng B J Eng Manuf:0954405417726811

  2. Wyen C, Wegener K (2010) Influence of cutting edge radius on cutting forces in machining titanium. CIRP Ann Manuf Technol 59(1):93–96

    Article  Google Scholar 

  3. Backer WR, Marshall ER, Shaw MC (1952) The size effect in metal cutting. J Manuf Sci Eng 74(1):61–72

    Google Scholar 

  4. Shaw MC (2003) The size effect in metal cutting. Sadhana 28(5):875–896

    Article  Google Scholar 

  5. Zhang T, Liu Z, Shi Z, Xu C (2017) Investigation on size effect of specific cutting energy in mechanical micro-cutting. Int J Adv Manuf Technol 91(5-8):2621–2633

    Article  Google Scholar 

  6. Fang F, Xu F, Lai M (2015) Size effect in material removal by cutting at nano scale. Int J Adv Manuf Technol 80(1-4):591–598

    Article  Google Scholar 

  7. De Oliveira FB, Rodrigues AR, Coelho RT, De Souza AF (2015) Size effect and minimum chip thickness in micromilling. Int J Mach Tools Manuf 89:39–54

    Article  Google Scholar 

  8. Manjunathaiah J, Endres WJ (2000) A new model and analysis of orthogonal machining with an edge-radiused tool. J Manuf Sci Eng 122(3):286–287

    Article  Google Scholar 

  9. Joshi SS, Melkote SN (2004) An explanation for the size-effect in machining using strain gradient plasticity. J Manuf Sci Eng 126(4):679–684

    Article  Google Scholar 

  10. Liu K, Melkote SN (2006) Material strengthening mechanisms and their contribution to size effect in micro-cutting. J Manuf Sci Eng 128(3):1147–1156

    Google Scholar 

  11. Weber M, Hochrainer T, Gumbsch P, Autenrieth H, Delonnoy L, Schulze V, Löhe D, Kotschenreuther J, Fleischer J (2007) Investigation of size-effects in machining with geometrically defined cutting edges. Mach Sci Technol 11(4):447–473

    Article  Google Scholar 

  12. Mian A, Driver N, Mativenga P (2011) Identification of factors that dominate size effect in micro-machining. Int J Mach Tools Manuf 51(5):383–394

    Article  Google Scholar 

  13. Ahn IH, Moon SK, Hwang J (2016) An efficient way of investigating the intrinsic size effect in machining. Proc Inst Mech Eng B J Eng Manuf 230(9):1622–1629

    Article  Google Scholar 

  14. Denkena B, Biermann D (2014) Cutting edge geometries. CIRP Ann Manuf Technol 63(2):631–653

    Article  Google Scholar 

  15. Vipindas K, Anand KN, Mathew J (2018) Effect of cutting edge radius on micro end milling: force analysis, surface roughness, and chip formation. Int J Adv Manuf Technol 97(1):711–722. https://doi.org/10.1007/s00170-018-1877-1

    Article  Google Scholar 

  16. Karpat Y, Özel T (2008) Mechanics of high speed cutting with curvilinear edge tools. Int J Mach Tools Manuf 48(2):195–208

    Article  Google Scholar 

  17. Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge university press

  18. Özel T, Karpat Y, Srivastava A (2008) Hard turning with variable micro-geometry PcBN tools. CIRP Ann Manuf Technol 57(1):73–76

    Article  Google Scholar 

  19. Karpat Y, Özel T (2007) Analytical and thermal modeling of high-speed machining with chamfered tools. J Manuf Sci Eng 130 (1):011001-011001-011015. doi:https://doi.org/10.1115/1.2783282

  20. Lu X, Wang F, Jia Z, Si L, Zhang C, Liang SY (2017) A modified analytical cutting force prediction model under the tool flank wear effect in micro-milling nickel-based superalloy. Int J Adv Manuf Technol 91(9):3709–3716. https://doi.org/10.1007/s00170-017-0001-2

    Article  Google Scholar 

  21. Fu Z, Chen X, Mao J, Xiong T (2018) An analytical force mode applied to three-dimensional turning based on a predictive machining theory. Int J Mech Sci 136:94–105

    Article  Google Scholar 

  22. Moufki A, Dudzinski D, Le Coz G (2015) Prediction of cutting forces from an analytical model of oblique cutting, application to peripheral milling of Ti-6Al-4V alloy. Int J Adv Manuf Technol 81(1-4):615–626

    Article  Google Scholar 

  23. Ning J, Nguyen V, Liang SY (2019) Analytical modeling of machining forces of ultra-fine-grained titanium. Int J Adv Manuf Technol 101(1):627–636. https://doi.org/10.1007/s00170-018-2889-6

    Article  Google Scholar 

  24. Weng J, Zhuang K, Chen D, Guo S, Ding H (2017) An analytical force prediction model for turning operation by round insert considering edge effect. Int J Mech Sci 128:168–180

    Article  Google Scholar 

  25. Weng J, Zhuang K, Zhu D, Guo S, Ding H (2018) An analytical model for the prediction of force distribution of round insert considering edge effect and size effect. Int J Mech Sci 138-139:86–98. https://doi.org/10.1016/j.ijmecsci.2018.01.024

    Article  Google Scholar 

  26. Zhuang K, Weng J, Zhu D, Ding H (2018) Analytical modeling and experimental validation of cutting forces considering edge effects and size effects with round chamfered ceramic tools. J Manuf Sci Eng 140 (8):081012-081012-081016. doi:https://doi.org/10.1115/1.4040087

  27. Molinari A, Moufki A (2005) A new thermomechanical model of cutting applied to turning operations. Part I. Theory. Int J Mach Tools Manuf 45(2):166–180

    Article  Google Scholar 

  28. Armarego EJA, Brown RH (1969) The machining of metals. Prentice Hall, Englewood Cliffs

    Google Scholar 

  29. Denkena B, Koehler J, Rehe M (2012) Influence of the honed cutting edge on tool wear and surface integrity in slot milling of 42CrMo4 steel. Procedia CIRP 1:190–195

    Article  Google Scholar 

  30. Abdelmoneim ME, Scrutton R (1974) Tool edge roundness and stable build-up formation in finish machining. J Manuf Sci Eng 96(4):1258–1267

    Google Scholar 

  31. Johnson GR Cook WH A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In: Proceedings of the 7th International Symposium on Ballistics, 1983. vol 1983. The Hague, The Netherlands, pp 541–547

  32. Oxley P (1962) Shear angle solutions in orthogonal machining. Int J Mach Tools Manuf 2(3):219–229

    Article  Google Scholar 

  33. Li B, Wang X, Hu Y, Li C (2011) Analytical prediction of cutting forces in orthogonal cutting using unequal division shear-zone model. Int J Adv Manuf Technol 54(5-8):431–443

    Article  Google Scholar 

  34. Zhou L, Peng F, Yan R, Yao P, Yang C, Li B (2015) Analytical modeling and experimental validation of micro end-milling cutting forces considering edge radius and material strengthening effects. Int J Mach Tools Manuf 97:29–41

    Article  Google Scholar 

  35. Rao S, Shunmugam M (2012) Analytical modeling of micro end-milling forces with edge radius and material strengthening effects. Mach Sci Technol 16(2):205–227

    Article  Google Scholar 

  36. AdvantEdge TW User’s Manual Version 5.2 (2008) Third wave systems. Minneapolis,

  37. He G, Liu X, Wu C, Zhang S, Zou L, Li D (2016) Study on the negative chamfered edge and its influence on the indexable cutting insert’s lifetime and its strengthening mechanism. Int J Adv Manuf Technol 84(5):1229–1237. https://doi.org/10.1007/s00170-015-7778-7

    Article  Google Scholar 

Download references

Funding

This work is partially supported by the National Natural Science Foundation of China (51705385), the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2017019), and the Fundamental Research Funds for the Central Universities (2018-IVB-009).

Author information

Authors and Affiliations

  1. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Xing Dai & Han Ding

  2. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Kejia Zhuang

Authors
  1. Xing Dai
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kejia Zhuang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Han Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kejia Zhuang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dai, X., Zhuang, K. & Ding, H. A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718. Int J Adv Manuf Technol 105, 531–543 (2019). https://doi.org/10.1007/s00170-019-04212-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04212-0

Keywords

Search

Navigation