Problem Statement Simulation Of Cutting Force During High Speed End Milling Of Inconel 718.

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1.2 Problem Statement

Basically nickel alloys are known as strongest materials. This nickel alloys have higher resistance to corrosion and also to high temperature. Inconel 718 is a one of the example of a nickel-based alloy. These Inconel 718 alloys are highly resistance to heavy corrosive substances. Those properties of this alloys lead to applied widely in aerospace, gas turbine, nuclear reactor, chemical and petrochemical industries. The material that used in aerospace industry must have less surface microstructure dislocation. It is very important for the part that used in aerospace industry to have low surface microstructure dislocation Wessel, 2004. Inconel 718 is well known as a difficult-to-cut material, so usually there is higher cutting force acting on the Inconel 718 during the machining as compared to other less harder material Devillez, Schneider, Dominiak, Dudzinski, Larrouquere, 2007. The higher cutting force will cause the material to have higher surface microstructure dislocation especially in normal milling and turning machines Thakur, et al., 2009. Therefore, the high speed machining HSM is introduced in order to reduce the cutting force on the cutting tool. The HSM was claimed low cutting force during the machining operation. The depth of cut, feed rate and cutting speed are those several factors which act as main parameters of machining Soo, Aspinwall, Dewes, 2004. These parameters are very important in machining process to obtain a good surface finish. During the machining operation of Inconel 718, several of cutting force will produce due to change in the cutting parameter. The major problem faced by machinist during HSM of super alloys is short tool life. The force acting on the cutting tool leads to short tool life. The range of cutting tool life span is between 0.5min to 90min Huang Liang, 2005. According to Qian Hossan, 2007 stated that, notch wear, pitting, chipping, flanking are associated with cutting force. By applying the finite element method FEM in machining processes is one of the best way to investigate the different cutting force due to the changes in cutting parameters. The high speed end ball milling of Inconel 718 is can stimulate by using 3D Deform 4 software and the simulation results can used to determine the most significant parameter to produce lower cutting force. It is very difficult to decide the optimization of cutting parameters in real machining process due to a lot of cutting experiments need to be executed. The simulation is run based on the real machining operation.

1.3 Objectives