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Numerical study of the minimum uncut chip thickness in micro-machining of Inconel 718 based on Johnson–Cook isothermal model

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Abstract

Traditional machining in micro-scale still presents many challenges associated with bad chip formation, presence of high burrs, elevated tool wear and low surface quality. Most problems in micro-machining are a consequence of the size effect, which is the similarity in the scale sizes of the cutting-edge radius of the tool and the minimum uncut chip thickness (MUCT). Micro-machining tends to be even more challenging for low-machinability alloys, such as Inconel 718. Through the finite element method (FEM), it is possible to estimate the minimum uncut chip thickness of a material providing that the constitutive model that describes its elastoplastic behavior is known. Therefore, the objective of this contribution is to analyze the chip formation in orthogonal micro-cutting of Inconel 718 using numerical FEM simulations and the Johnson–Cook plasticity model in an explicit scheme. Two cutting tools were modelled with different edge radius in order to represent a sharp tool and a tool that suffered rounding of the tip because of wear. Simulations were carried out with different values of feed per tooth in order to determine which value is closest to MUCT. The Mises stress and accumulated plastic strain were monitored, as well as the cutting forces. The results show that the rounded tool, with an edge radius of 5 µm, leads to higher forces, worse chip formation and worse surface quality when compared to the sharp tool, with an edge radius of 1 µm.

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Funding

All authors would like to acknowledge the financial support provided by CAPES and CNPq. Lucival Malcher would also like to acknowledge the support from the Brazilian Council for the scientific and Technological Development-CNPq (contract 315215/2021–6).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Technology, University of Brasília, Campus Darcy Ribeiro, Asa Norte, Brasília, DF, Brazil

    Gabriel de Paiva Silva, Déborah de Oliveira & Lucival Malcher

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  1. Gabriel de Paiva Silva
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  2. Déborah de Oliveira
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  3. Lucival Malcher
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Contributions

Author Gabriel de Paiva Silva contributed to the theoretical development, numerical simulations and analysis of the results of the work. The author Deborah de Oliveira contributed with the theoretical development, providing micromachining data and simulation with hard precipitates. Author Lucival Malcher contributed by detailing the JC model, providing material properties, improving numerical simulations and analysis of the results.

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Correspondence to Lucival Malcher.

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de Paiva Silva, G., de Oliveira, D. & Malcher, L. Numerical study of the minimum uncut chip thickness in micro-machining of Inconel 718 based on Johnson–Cook isothermal model. Int J Adv Manuf Technol 127, 2707–2721 (2023). https://doi.org/10.1007/s00170-023-11573-0

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