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1

Modelling of material behaviour for Inconel 718 superalloy using experimental data

Nieslony P., Grzesik W., Laskowski P.

Journal of Machine Engineering

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2017

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Vol. 17, No. 3

75--84

EN

In this paper parameters of the Johnson-Cook (J-C) constitutive material model were predicted more accurately based on the static and dynamic material tests and mathematical modelling of relevant response surfaces using specially developed Matlab scripts. Experimental tests were performed under strain rates of 10-3 and 101 1/s and the temperature ranging from the ambient up to 700°C. As a result, a set of mathematical models which fit the experimental data was determined. The experimentally-derived constitutive models were implemented into FEM-based simulations of real machining processes of Inconel 718.

2

Analysis of mechanical characteristics of face milling process of Ti6AI4V alloy using experimental and simulation data

Nieslony P., Grzesik W., Bartoszuk M., Habrat W.

Journal of Machine Engineering

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2016

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Vol. 16, No. 3

58--66

EN

This paper presents experimental and 3D FEM simulation results obtained for the Johnson-Cook material constitutive model and variable cutting conditions. Face milling tests were carried out using a Ti6Al4V titanium alloy as the workpiece and coated carbide indexable inserts. CAD models of the cutting tool insert and the face milling head were generated and implemented into FEM package used. The machining conditions were selected based on real production data from aerospace sector. In particular, changes of power and specific cutting energy were analyzed in terms of the rotation angle of the milling head and the ratio of the uncut chip thickness against the cutting edge radius.

3

Numerical 3D FEM Simulation and Experimental Analysis of Tribological Aspects in Turning Inconel 718 Alloy

Nieslony P., Grzesik W., Laskowski P, Zak K.

Journal of Machine Engineering

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2015

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Vol. 15, No. 1

46--57

EN

This paper presents 3D FEM simulation results performed for the power law and JC (Johnson-Cook) material constitutive models for two sets of friction parameters. The friction conditions were tested using pin-on-disc tribometer. Machining tests were carried out using carbide cutting tools coated with a TiAlN monolayer without coolants. The selection of machining conditions was based on real production data. In addition, a real CAD model of the cutting tool insert was implemented. Moreover, an advanced technique of meshing the cutting edge and the grooved rake face was applied. The simulations include cutting forces and cutting temperature. Finally, FEM simulations were compared with measurements in order to improve the simulation strategy.

4

Influence of Cutting Conditions on Temperature Distribution in Face Milling of Inconel 718 Nickel-Chromium Alloy

Grzesik W., Nieslony P., Habrat W., Laskowski P.

Journal of Machine Engineering

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2015

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Vol. 15, No. 2

5--16

EN

This paper presents 3D FEM simulation results obtained for the milling operations on a nickel-chromium alloy (Inconel 718) using the Johnson-Cook material constitutive model and variable cutting conditions. Face milling tests were carried out using silicon-aluminum-oxygen-nitrogen (SiAlON) ceramic cutting tools inserts. The machining conditions were selected based on real production data (cutting speed of vc=750 and 800 m/min, feed of f=0.1, 0.125 and 0.15 mm/t, depth of cut of ap=1, 1.5 and 2 mm). The FEM simulations include the maximum and average values of the cutting temperature. They were compared with experimental data obtained by using the high speed infra-red camera.

5

Determination of tool life and research wear during duplex stainless steel turning

Krolczyk G. M., Nieslony P., Legutko S.

Archives of Civil and Mechanical Engineering

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2015

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Vol. 15, no. 2

347--354

EN

The purpose of the study is to determine the coated carbides tool life and the tool point surface topography. The study determined the cutting conditions in the process of turning duplex stainless steel (DSS), and detailed identification of wear mechanisms occurring on the rake face and major flank. The results of wear occurring on both tool points were compared with the width of the flank wear in relation to the period of the steady-state wear of the tool point. Occurrences of various mechanisms have been proven, such as abrasive wear and adhesion wear. Where machining without the use of a cooling lubricant occurred, longer tool life has been determined as well as a greater resistance to abrasive wear of the tools which were coated with Al2O3. Scanning electron microscopy (SEM) has been used for the wear analysis.

6

3D FEM simulations and experimental studies of the turning process of Inconel 718 superalloy

Nieslony P., Grzesik W., Żak K., Laskowski P.

Journal of Machine Engineering

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2014

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Vol. 14, No. 2

16--26

EN

This paper is focused on the finite element analysis of machining of Inconel 718 superalloy in a non-orthogonal (3D) turning process. The cutting experiments were carried out on the cylindrical workpiece of Inconel 718 with the cutting speed of 60-90 m/min, the feed rate of 0.1 mm/rev and different depths of cut. The FEM simulations include the average and maximum interface temperatures, the resultant cutting force and its three components and the chip thickness obtained for the 3D turning process. The simulation results were compared with experimental data obtained in the non-orthogonal process. It was found that the experimental values of the cutting forces are underestimated (about 23-30%) in relation to the FEM simulation data. Additionally, it was noted that the cutting depth has a significant effect on the average interface temperature only when using a non-orthogonal turning process.