Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Nickel-based superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges because of the significantly increased cutting force and vibration, since Inconel 718 is a typical difficult-to-machine material. This paper takes the milling process of Inconel 718 as the research object, initially, and a milling force model of Inconel 718 is established. Subsequently, the finite element analysis method is used to analyze the stress field, temperature field, and milling force in the milling process of Inconel 718. Building upon this, a dynamic equation of the milling of Inconel 718 is established, and based on the modal experiment, stability lobe diagrams are drawn. Furthermore, milling experiments on Inconel 718 are designed, and the results calculated using the milling force model and finite element analysis are verified through comparison to the experimental results; then, the fmincon optimization algorithm is used to optimize the processing parameters of Inconel 718. Eventually, the results of the multi-objective optimization illustrate that the best processing parameters are a spindle speed of 3199.2 rpm and a feed speed of 80 mm/min with an axial depth of cut of 0.25 mm. Based on this, the best machining parameters are determined, which point towards an improvement of the machining efficiency and quality of Inconel 718.