Modelling the orthogonal machining process using coated cemented carbide cutting tools

Finite element methods were used to model the effect of coated and uncoated, cemented carbide cutting tools on the machinability of the nickel-based superalloy Inconel 718. Disposable coated and uncoated carbide inserts were used both experimentally and as finite element analysis (FEA) models to study how the stress distribution within different coatings and carbide grades compared to each other under a range of cutting conditions. The simulation of an orthogonal metal cutting process was performed using FORGE2, an elasto-plastic FEA package. All finite element models were assumed to be plane strain. The results include the stress and temperature distributions through the primary shear zone, the chip/tool contact region and the coating/substrate boundaries. The tool wear and stress distribution results from the finite element modelling agree favourably with those obtained from experimental work.