Skip to main content
SpringerLink
Log in

Inverse analysis of the cutting force in laser-assisted milling on Inconel 718

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

Abstract

Inverse analysis is of value identifying viable solutions of process parameters that can achieve specified process performance. In this study, an inverse analysis method is proposed for the cutting force in laser-assisted milling on Inconel 718. The method uses the analytical model to solve the direct problem and applies a variance-based recursive method to guide the inverse analysis. The half-slot milling is simplified as an orthogonal cutting at each instant, forces in cutting and radial directions are calculated under microstructure evolution, and the axial force is predicted according to tool geometry and coordinates transformation. The inverse analysis identifies five process parameters including feed rate, axial depth of milling, laser preheating temperature, spindle speed, and rake angle, and finds the optimal solution for target performance, the resultant cutting force. Four experiments verified the effectiveness of the proposed method because of a maximum error less than 8% between predicted forces and experimental measurements. The proposed method is valuable in terms of providing a reference for the selection of process parameters under certain cutting force requirements.

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

Similar content being viewed by others

References

  1. Pan Z et al (2017) Force modeling of Inconel 718 laser-assisted end milling under recrystallization effects. Int J Adv Manuf Technol:1–10

  2. Pan Z, Feng Y, Lu YT, Lin YF, Hung TP, Hsu FC, Lin CF, Lu YC, Liang SY (2017) Microstructure-sensitive flow stress modeling for force prediction in laser assisted milling of Inconel 718. Manuf Rev 4:6. https://doi.org/10.1051/mfreview/2017005

    Google Scholar 

  3. Lorphèvre ERE, Filippi E, Dehombreux P (2007) Inverse method for cutting forces parameters evaluation. Eng Mech 14(5):1–13

    Google Scholar 

  4. Carvalho SRD et al (2009) Comparison of inverse methods in the determination of heat flux and temperature in cutting tool during a machining process. High Temp High Press 38:119–136

    Google Scholar 

  5. Santos MRd, Lima e Silva SMM, Machado ÁR, Silva MB, Guimarães G, Carvalho SR (2014) Analyses of effects of cutting parameters on cutting edge temperature using inverse heat conduction technique. Math Probl Eng 2014:1–11. https://doi.org/10.1155/2014/871859

    Article  Google Scholar 

  6. Pujana J, Arrazola PJ, M’Saoubi R, Chandrasekaran H (2007) Analysis of the inverse identification of constitutive equations applied in orthogonal cutting process. Int J Mach Tools Manuf 47(14):2153–2161. https://doi.org/10.1016/j.ijmachtools.2007.04.012

    Article  Google Scholar 

  7. Agmell M, Ahadi A, Ståhl J-E (2014) Identification of plasticity constants from orthogonal cutting and inverse analysis. Mech Mater 77:43–51. https://doi.org/10.1016/j.mechmat.2014.07.005

    Article  Google Scholar 

  8. Franchi R, del Prete A, Umbrello D, Mariano E (2015) Inverse analysis procedure to determine flow stress and friction data for metal cutting finite element modeling. Key Eng Mater 651-653:1345–1350. https://doi.org/10.4028/www.scientific.net/KEM.651-653.1345

    Article  Google Scholar 

  9. Laakso SV, Niemi E Using FEM simulations of cutting for evaluating the performance of different Johnson-Cook parameter sets acquired with inverse methods. In: Oduoza CF (ed) Proceedings of the 25th International Conference on Flexible Automation and Intelligent Manufacturing, Designing for Advanced, High Value Manufacturing and Intelligent Systems for the 21st Century, FAIM 2015. 2015. The Choir Press, Wolverhampton, pp 172–180

  10. Denkena B, Grove T, Dittrich MA, Niederwestberg D, Lahres M (2015) Inverse determination of constitutive equations and cutting force modelling for complex tools using Oxley’s predictive machining theory. Procedia CIRP 31:405–410. https://doi.org/10.1016/j.procir.2015.03.012

    Article  Google Scholar 

  11. Bäker M (2015) A new method to determine material parameters from machining simulations using inverse identification. Procedia CIRP 31:399–404. https://doi.org/10.1016/j.procir.2015.04.090

    Article  Google Scholar 

  12. Chen X et al (2017) Determining Al6063 constitutive model for cutting simulation by inverse identification method. Int J Adv Manuf Technol:1–8

  13. Oxley PLB (1989) Mechanics of machining, an analytical approach to assessing machinability. ELLIS Horwood Limited:242

  14. Pan Z, Feng Y, Liang S (2017) Material microstructure affected machining: a review. Manuf Rev 4:5. https://doi.org/10.1051/mfreview/2017004

    Google Scholar 

  15. Jafarian F, Imaz Ciaran M, Umbrello D, Arrazola PJ, Filice L, Amirabadi H (2014) Finite element simulation of machining Inconel 718 alloy including microstructure changes. Int J Mech Sci 88:110–121. https://doi.org/10.1016/j.ijmecsci.2014.08.007

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    Yixuan Feng & Steven Y. Liang

  2. Metal Industries Research and Development Centre (MIRDC), Kaohsiung, Taiwan

    Yu-Ting Lu, Yu-Fu Lin, Tsung-Pin Hung, Fu-Chuan Hsu, Chiu-Feng Lin & Ying-Cheng Lu

Authors
  1. Yixuan Feng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yu-Ting Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yu-Fu Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Tsung-Pin Hung
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Fu-Chuan Hsu
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Chiu-Feng Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Ying-Cheng Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Steven Y. Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yixuan Feng.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Feng, Y., Lu, YT., Lin, YF. et al. Inverse analysis of the cutting force in laser-assisted milling on Inconel 718. Int J Adv Manuf Technol 96, 905–914 (2018). https://doi.org/10.1007/s00170-018-1670-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1670-1

Keywords

Search

Navigation