Título:	Numerical study of the minimum uncut chip thickness in micro‑machining of Inconel 718 based on Johnson–Cook isothermal model
Autor(es):	Silva, Gabriel de Paiva Oliveira, Déborah de Malcher, Lucival
ORCID:	https://orcid.org/0000-0002-3654-4953
Afiliação do autor:	University of Brasília, Faculty of Technology, Department of Mechanical Engineering University of Brasília, Faculty of Technology, Department of Mechanical Engineering University of Brasília, Faculty of Technology, Department of Mechanical Engineering
Assunto:	Método dos elementos finitos Plasticidade
Data de publicação:	7-Jun-2023
Editora:	Springer
Referência:	SILVA, Gabriel de Paiva; OLIVEIRA, Déborah de; MALCHER, Lucival. Numerical study of the minimum uncut chip thickness in micro‑machining of Inconel 718 based on Johnson–Cook isothermal model. The International Journal of Advanced Manufacturing Technology, [S. l.], v. 127, p. 2707–2721, 2023. DOI: https://doi.org/10.1007/s00170-023-11573-0.
Abstract:	Traditional machining in micro-scale still presents many challenges associated with bad chip formation, presence of high burrs, elevated tool wear and low surface quality. Most problems in micro-machining are a consequence of the size efect, which is the similarity in the scale sizes of the cutting-edge radius of the tool and the minimum uncut chip thickness (MUCT). Micro-machining tends to be even more challenging for low-machinability alloys, such as Inconel 718. Through the fnite ele ment method (FEM), it is possible to estimate the minimum uncut chip thickness of a material providing that the constitutive model that describes its elastoplastic behavior is known. Therefore, the objective of this contribution is to analyze the chip formation in orthogonal micro-cutting of Inconel 718 using numerical FEM simulations and the Johnson–Cook plasticity model in an explicit scheme. Two cutting tools were modelled with diferent edge radius in order to represent a sharp tool and a tool that sufered rounding of the tip because of wear. Simulations were carried out with diferent values of feed per tooth in order to determine which value is closest to MUCT. The Mises stress and accumulated plastic strain were monitored, as well as the cutting forces. The results show that the rounded tool, with an edge radius of 5 µm, leads to higher forces, worse chip formation and worse surface quality when compared to the sharp tool, with an edge radius of 1 µm.
Unidade Acadêmica:	Faculdade de Tecnologia (FT) Departamento de Engenharia Mecânica (FT ENM)
Programa de pós-graduação:	Programa de Pós-Graduação em Ciências Mecânicas
DOI:	https://doi.org/10.1007/s00170-023-11573-0
Versão da editora:	https://link.springer.com/article/10.1007/s00170-023-11573-0
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