3D FEM simulations and experimental studies of the turning process of Inconel 718 superalloy

This paper is focused on the finite element analysis of machining of Inconel 718 superalloy in a non-orthogonal (3D) turning process. The cutting experiments were carried out on the cylindrical workpiece of Inconel 718 with the cutting speed of 60-90 m/min, the feed rate of 0.1 mm/rev and different depths of cut. The FEM simulations include the average and maximum interface temperatures, the resultant cutting force and its three components and the chip thickness obtained for the 3D turning process. The simulation results were compared with experimental data obtained in the non-orthogonal process. It was found that the experimental values of the cutting forces are underestimated (about 23-30%) in relation to the FEM simulation data. Additionally, it was noted that the cutting depth has a significant effect on the average interface temperature only when using a non-orthogonal turning process.