The effect of chip formation on the cutting force and tool wear in high-speed milling Inconel 718

Coated carbide tools are widely used in the processing of nickel-based superalloys due to their excellent wear resistance, high strength, and good hardness at high temperatures. In this paper, the high-speed milling experiments and finite element simulation of Inconel 718 are carried out by using PVD TiAlN-coated carbide tools. Simulations of tool temperature, cutting force, and chip morphology were performed to analyze the effect of cutting speed on the degree of sawtooth chip formation and the effect of sawtooth chip formation on the cutting force and tool wear. The results show that the cutting temperature mainly focuses on the rake face, and with the cutting speed increasing from 60 to 120 m/min, the maximum temperature of the rake face increases from 580 to 660 celcius. The maximum temperature region (MTR) on the rake face gradually approaches the tool nose with a decrease in the cutting speed. The generation of sawtooth chips leads to fluctuations in the cutting force component. As the cutting speed increases, the degree of chip sawing increases. The effect of the sawtooth chip on the fluctuation of the cutting force will also increase, thus increasing the degree of tool wear.