Analytical and Numerical Modeling of Hot Machining of Inconel 718
American Journal of Mechanical and Materials Engineering
Volume 1, Issue 2, June 2017, Pages: 49-57
Received: Mar. 13, 2017; Accepted: Apr. 8, 2017; Published: Jun. 2, 2017
Views 2051      Downloads 203
Asit Kumar Parida, Mechanical Engineering Department, National Institute of Technology Rourkela, Odisha, India
Article Tools
Follow on us
The comparison of an analytical and numerical method to calculate the plastic strain, shear angle, and chip tool contact length in hot machining of Inconel 718 using flame heating has been discussed in the present study. The workpiece was heated with the combination of liquid petroleum gas along with oxygen gas. Merchant analytical model has been utilized for calculation of plastic strain, shear angle, while Sutter model is used for chip-tool contact length. DEFORM software has been used to find out the chip-tool contact length (L), shear angle (Φ), shear strain (ε) in the numerical model. It was observed that shear angle and chip tool contact length increased and plastic strain decreased with the increase of cutting speed and feed rate. From the numerical study, a good correlation was found for shear angle, chip tool contact length with the analytical model.
FEM, Plastic Strain, Inconel 718, Shear Angle, Chip-Tool Contact Length
To cite this article
Asit Kumar Parida, Analytical and Numerical Modeling of Hot Machining of Inconel 718, American Journal of Mechanical and Materials Engineering. Vol. 1, No. 2, 2017, pp. 49-57. doi: 10.11648/j.ajmme.20170102.14
Copyright © 2017 Authors retain the copyright of this article.
This article is an open access article distributed under the Creative Commons Attribution License ( which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Ezugwu EO. High speed machining of aero-engine alloys. J Brazilian Soc Mech Sci Eng 2004;26:1–11. doi:10.1590/S1678-58782004000100001.
Ezugwu EO. Key improvements in the machining of difficult-to-cut aerospace superalloys. Int J Mach Tools Manuf 2005;45:1353–67. doi:10.1016/j.ijmachtools.2005.02.003.
Nurul Amin AKM, Ginta TL. Heat-Assisted Machining. vol. 11. 2014. doi:10.1016/B978-0-08-096532-1.01118-3.
Ginta TL, Amin AKMN. Thermally-assisted end milling of titanium alloy Ti-6Al-4V using induction heating. Int J Mach Mach Mater 2013;14:194–212. doi:10.1504/IJMMM.2013.055737.
Hinds BK, Almeida SM. Plasma arc heating for hot machining. Int J Mach Tool Des Res 1981;21:143–52. doi:10.1016/0020-7357(81)90005-6.
Patten JA, Ghantasala M, Shayan AR, Poyraz HB, Ravindra D. Micro-Laser Assisted Machining (µ-LAM): Scratch Tests on 4H-SiC 2009.
Pal DK, Basu SK. Hot machining of austenitic manganese steel by shaping. Int J Mach Tool Des Res 1971;11:45–61. doi:10.1016/0020-7357(71)90046-1.
Parida AK, Maity KP. An experimental investigation to optimize multi-response characteristics of Ni-hard material using hot machining. Adv Eng Forum 2016;16:16–23. doi:10.4028/
Maity KP, Swain PK. An experimental investigation of hot-machining to predict tool life. J Mater Process Technol 2008;198:344–9. doi:10.1016/j.jmatprotec.2007.07.018.
Lei S, Pfefferkorn F. A review of thermally assisted machining. ASME Int Conf Manuf Sci Eng (MSEC 2007) 2007:325–36. doi:10.1115/MSEC2007-31096.
Davim JP, Maranh C. A study of plastic strain and plastic strain rate in machining of steel AISI 1045 using FEM analysis. Mater Des 2009;30:160–5. doi:10.1016/j.matdes.2008.04.029.
Duan CZ, Wang MJ, Pang JZ, Li GH. A calculational model of shear strain and strain rate within shear band in a serrated chip formed during high speed machining. J Mater Process Technol 2006;178:274–7. doi:10.1016/j.jmatprotec.2006.04.008.
Ghadbeigi H, Bradbury SR, Pinna C, Yates JR. Determination of micro-scale plastic strain caused by orthogonal cutting. Int J Mach Tools Manuf 2008;48:228–35. doi:10.1016/j.ijmachtools.2007.08.017.
Parida AK, Maity KP. Effect of nose radius on forces, and process parameters in hot machining of Inconel 718 using finite element analysis. Eng Sci Technol an Int J 2016:4–10. doi:10.1016/j.jestch.2016.10.006.
Toropov A, Ko SL. Prediction of tool-chip contact length using a new slip-line solution for orthogonal cutting. Int J Mach Tools Manuf 2003;43:1209–15. doi:10.1016/S0890-6955(03)00155-X.
Zadshakoyan M, Pourmostaghimi V. Cutting tool crater wear measurement in turning using chip geometry and genetic programming. Int J Appl Metaheuristic Comput 2015;6:47–60. doi:10.4018/ijamc.2015010104.
Iqbal SA, Mativenga PT, Sheikh MA. A comparative study of the tool-chip contact length in turning of two engineering alloys for a wide range of cutting speeds. Int J Adv Manuf Technol 2009;42:30–40. doi:10.1007/s00170-008-1582-6.
Parida AK, Maity KP. Finite element method and experimental investigation of hot turning of Inconel 718. Adv Eng Forum 2016;16:24–32. doi:10.4028/
Parida AK, Maity KP. Optimization of multi-responses in hot turning of Inconel 625 alloy using DEA-Taguchi approach. Int J Eng Res Africa 2016;24:57–63. doi:10.4028/
Parida AK, Maity KP. Optimization in hot turning of nickel based alloy using desirability function analysis. Int J Eng Res Africa 2016;24:64–70. doi:10.4028/
Sun S, Brandt M, Dargusch MS. Thermally enhanced machining of hard-to-machine materialsA review. Int J Mach Tools Manuf 2010;50:663–80. doi:10.1016/j.ijmachtools.2010.04.008.
Leshock CE, Kim JN, Shin YC. Plasma enhanced machining of Inconel 718: Modeling of workpiece temperature with plasma heating and experimental results. Int J Mach Tools Manuf 2001;41:877–97. doi:10.1016/S0890-6955(00)00106-1.
Novak JW, Shin YC, Incropera FP. Assessment of plasma enhanced machining for improved machinability of Inconel 718. J Manuf Sci Eng 1997;119:125. doi:10.1115/1.2836550.
Shi B, Attia H, Vargas R, Tavakoli S. Numerical and experimental investigation of laser-assisted machining of Inconel 718. Mach Sci Technol 2008;12:498–513. doi:10.1080/10910340802523314.
Yilbas BS, Akhtar SS, Karatas C. Laser surface treatment of Inconel 718 alloy: Thermal stress analysis. Opt Lasers Eng 2010;48:740–9. doi:10.1016/j.optlaseng.2010.03.012.
Sutter G. Chip geometries during high-speed machining for orthogonal cutting conditions. Int J Mach Tools Manuf 2005;45:719–26. doi:10.1016/j.ijmachtools.2004.09.018.
Joshi S, Tewari A, Joshi SS. Microstructural characterization of chip segmentation under different Machining environments in orthogonal machining of Ti6Al4V. J Eng Mater Technol 2015;137:11005. doi:10.1115/1.4028841.
Uhlmann E, Von Der Schulenburg MG, Zettier R. Finite element modeling and cutting simulation of inconel 718. CIRP Ann - Manuf Technol 2007;56:61–4. doi:10.1016/j.cirp.2007.05.017.
Özel T, Ulutan D. Prediction of machining induced residual stresses in turning of titanium and nickel based alloys with experiments and finite element simulations. CIRP Ann - Manuf Technol 2012;61:547–50. doi:10.1016/j.cirp.2012.03.100.
Singh G, Teli M, Samanta A, Singh R, Singh G, Teli M,. Finite element modeling of laser-assisted machining of AISI D2 tool steel. Materials and Manufacturing engineering, 2015;6914. doi:10.1080/10426914.2012.700160.
Science Publishing Group
1 Rockefeller Plaza,
10th and 11th Floors,
New York, NY 10020
Tel: (001)347-983-5186