Micro-milling Force Prediction of Inconel 718 Thin-walled Parts

Inconel 718 mesoscopic thin-walled parts are in increasing demands in aerospace, medicine, communication equipment and other fields. Thin-wall micro-milling deformation is a difficult problem in the field, and micro-milling force is an important factor causing machining deformation. In order to predict the force of thin-wall micro-milling, the finite element simulation model of Inconel 718 thin-wall micro-milling process was established together with the geometric models of the micro-milling tool and thin-wall parts, the mesh division was completed, and the mesh independence was verified. The Johnson-Cook constitutive model and failure criterion were used to describe the material constitutive relationship and chip separation criterion respectively. The modified Coulomb model was used to describe the friction characteristics. The results show that the maximum and average relative errors are 11. 23% and 7. 04%, respectively, by comparing the micro milling force output of the simulation model with the experimental results, which verifies the effectiveness and accuracy of the model. © 2023 Northeastern University. All rights reserved.