Experimental and thermomechanical SPH and FEA model simulation using inconel 825 with tungsten carbide tool

Abstract

This study introduces an integrated experimental and finite element analysis (FEA) simulation methodology for improving the turning process of Inconel 825 using tungsten carbide (WC) cutting tools. The research presents an innovative framework that integrates infrared thermal imaging with numerical simulations to examine transient temperature profiles and cutting forces across different machining settings. This study systematically examines the effects of feed rate, cutting speed, and depth of cut on thermal and mechanical responses, employing an L9 orthogonal array for experimental design, in contrast to usual investigations. This research’s primary innovation is the exact monitoring of interface temperatures with an infrared thermal camera, yielding precise thermal data despite the difficulties posed by expensive materials and real-time heat dissipation assessment. The FEA simulations performed in Abaqus FEA utilize an elastoplastic material model exhibiting nonlinear behavior, effectively capturing yielding in both tension and compression. The results demonstrate a robust connection between experimental and numerical findings, with cutting force predictions differing by less than 5%. The research indicates that raising the cutting speed lowers cutting forces while influencing temperature patterns in a non-linear manner. The research underscores the significance of WC inserts in augmenting heat dissipation and promoting machining stability. The proven FEA framework provides a dependable prediction instrument for optimizing machining settings, hence enhancing process control and precision manufacture of high-strength alloys.