Simulation analysis of cutting process for Inconel718 nickel-based superalloy

As a difficult-to-machine material, Inconel718 nickel-based superalloy is widely used in aerospace, ocean navigation, and large-scale manufacturing of machines. In this paper, based on ABAQUS software, the continuous milling process of Inconel718 is simulated and analyzed, and related issues are discussed, including model establishment, material parameters, and meshing techniques during milling. The simulation results revealed that the heat generated during the milling process increases continuously with the increase in rotational speed. A majority of the generated heat is transferred to the chips and the workpiece, and a minor part is transferred to the tool. During the milling process, the temperature distribution on the cutting tool changes in a gradient, and the temperature of the tool is lower than that of the workpiece. Furthermore, it is observed that the cutting parameters that have the strongest influence on the cutting force and cutting temperature are feed per tooth and spindle speed, respectively. Therefore, in actual processing, speed and feed per tooth can be controlled to get better processing efficiency. Compared to the previous studies, it is concluded that three-dimensional simulation analysis of difficult-to-machine materials can reduce unnecessary wastage of resources and can provide better guidance for actual production and efficient milling.