FEM Simulation of Orthogonal Machining of Al 6101-T6 and Inconel 718 Using Johnson-Cook Constitutive Model

Resumo

Traditional machining processes such as milling and turning consist in using a cutting tool with defined
geometry to give shape to a workpiece by removing material in the form of chips. The Finite Element Method
(FEM) can be used to simulate the metal cutting procedure and predict output variables such as chip morphology
and cutting forces, facilitating the optimization of machining parameters and reducing experimental costs. Thus,
the present work aims to simulate machining operations to conduct a numerical analysis of chip morphology and
cutting forces in different materials. The nickel superalloy Inconel 718, which is considered a hard-to-cut material,
was chosen for a comparative study with the aluminum alloy Al 6101-T6, considered a material of good
machinability. The mechanical properties of both materials were characterized using the Johnson-Cook
constitutive model in the simulations, whereas the cutting tool was modelled as a rigid body. The results show that
machining of Inconel 718 leads to worse chip formation, higher residual stresses, and higher cutting forces than
Al 6101-T6, which is expected from literature.