Microstructure-Based Flow Stress Model to Predict Machinability of Inconel 718

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Inconel 718 is crucial in aerospace, aviation, and marine industries due to its high-temperature properties.
• Understanding Inconel 718's high strain rate and temperature behavior is vital for manufacturing.
• Machining processes induce large strain deformations in Inconel 718.

Purpose of the Study:

• To develop a physics-based constitutive model for Inconel 718.
• To simulate the plastic behavior of Inconel 718 during machining.
• To quantitatively predict machinability using a microstructure-based flow stress model.

Main Methods:

• Developed a physics-based constitutive model incorporating dislocation motion and density evolution.
• Utilized a microstructure-based flow stress model.
• Compared model predictions with orthogonal cutting experimental results.

Main Results:

• The model accurately simulates the plastic behavior of Inconel 718 under large strain deformations.
• Quantitative predictions of cutting forces and temperatures during machining were achieved.
• Model predictions showed a high degree of accuracy, with a 5-8% margin of error.

Conclusions:

• The developed model reliably predicts the high-speed machining dynamics of Inconel 718.
• The model enhances the understanding of Inconel 718's behavior in manufacturing.
• The findings support improved process design and optimization for Inconel 718 components.