Numerical-simulation hybrid analysis of orthogonal cutting of Inconel 718
DOI:
https://doi.org/10.15282/jmes.20.1.2026.2.0862Keywords:
Johnson-Cook failure model, Response surface method, Machining, Multi objective optimization, Chip formation, cutting forceAbstract
Inconel 718 is widely employed in the aerospace and energy sectors due to its exceptional mechanical and thermal stability, yet it remains one of the most challenging materials to machine. This study develops and validates a comprehensive three-dimensional finite element model using ANSYS to simulate orthogonal cutting of Inconel 718. The developed model incorporates Johnson-Cook constitutive and damage laws to represent strain hardening, rate sensitivity, thermal softening, and failure behaviour under high-speed cutting conditions. A full factorial design combined with response surface methodology was employed to analyze how variations in cutting speed, rake angle, nose radius, clearance angle, and depth of cut affect key machining responses, including cutting force, von Mises stress, cutting temperature, and energy consumption. Simulation outputs were rigorously validated against available experimental data, achieving close agreement. Parametric and ANOVA analyses revealed that rake angle and cutting speed significantly affect chip segmentation and thermal gradients. Empirical regression models demonstrated high predictive accuracy and were used for multi-objective optimization, yielding an optimal parameter set that minimized cutting force, energy, and thermal load. The findings provide a validated, computationally efficient simulation framework with direct relevance to machining process optimization and tool performance prediction in superalloy applications.
References
[1] A. Barcelo Singh, “Oxidation resistance of additively manufactured Inconel 718 for gas turbine applications,” Doctoral dissertation, Carleton University, 2020.
[2] G. Gudivada and A. K. Pandey, “Recent developments in nickel-based superalloys for gas turbine applications,” Journal of Alloys and Compounds, vol. 963, p. 171128, 2023.
[3] Q. Yin, Z. Liu, B. Wang, Q. Song, and Y. Cai, “Recent progress of machinability and surface integrity for mechanical machining Inconel 718: a review,” The International Journal of Advanced Manufacturing Technology, vol. 109, pp. 215–245, 2020.
[4] C. Liu, M. Wan, W. Zhang, and Y. Yang, “Chip formation mechanism of Inconel 718: a review of models and approaches,” Chinese Journal of Mechanical Engineering, vol. 34, pp. 1–16, 2021.
[5] K. Mahesh, J. T. Philip, S. N. Joshi, and B. Kuriachen, “Machinability of Inconel 718: A critical review on the impact of cutting temperatures,” Materials and Manufacturing Processes, vol. 36, no. 7, pp. 753–791, 2021.
[6] C. Liu, M. Wan, and Y. Yang, “Simulation of the chip morphology together with its evolution in machining of Inconel 718 by considering widely spread cutting speed,” The International Journal of Advanced Manufacturing Technology, vol. 116, pp. 175–195, 2021.
[7] C. Pérez-Salinas, L. N. L. de Lacalle, A. del Olmo, and C. S. Kumar, “The relationship between the cutting-edge, tool wear and chip formation during Inconel 718 dry cutting,” The International Journal of Advanced Manufacturing Technology, vol. 132, no. 11, pp. 6001–6017, 2024.
[8] Z. Hao, B. Mu, and Y. Fan, “Cross-scale constitutive description and deformation mechanism in cutting nickel-based superalloy Inconel718,” International Journal of Material Forming, vol. 18, no. 1, pp. 1–29, 2025.
[9] G. Arndt and R. H. Brown, “On the temperature distribution in orthogonal machining,” International Journal of Machine Tool Design and Research, vol. 7, no. 1, pp. 39–53, 1967.
[10] A. F. Pedroso, N. P. Sebbe, R. D. Costa et al., “INCONEL® alloy machining and tool wear finite element analysis assessment: an extended review,” Journal of Manufacturing and Materials Processing, vol. 8, no. 1, p. 37, 2024.
[11] M. Movahhedy, M. S. Gadala, and Y. Altintas, “Simulation of the orthogonal metal cutting process using an arbitrary Lagrangian–Eulerian finite-element method,” Journal of Materials Processing Technology, vol. 103, no. 2, pp. 267–275, 2000.
[12] O. Pantalé, J. L. Bacaria, O. Dalverny, R. Rakotomalala, and S. Caperaa, “2D and 3D numerical models of metal cutting with damage effects,” Computer Methods in Applied Mechanics and Engineering, vol. 193, no. 39-41, pp. 4383–4399, 2004.
[13] T. Ozel, I. Llanos, J. Soriano, and P. J. Arrazola, “3D finite element modelling of chip formation process for machining Inconel 718: comparison of FE software predictions,” Machining Science and Technology, vol. 15, no. 1, pp. 21–46, 2011.
[14] X. Wang, C. Huang, B. Zou, H. Liu, H. Zhu, and J. Wang, “Dynamic behavior and a modified Johnson Cook constitutive model of Inconel 718 at high strain rate and elevated temperature,” Materials Science and Engineering: A, vol. 580, pp. 385–390, 2013.
[15] F. Yi, R. Zhong, W. Zhu, R. Zhou, L. Guo, and Y. Wang, “Comparative study of friction in high-speed machining of titanium model alloys,” Lubricants, vol. 13, no. 3, p. 113, 2025.
[16] W. B. Palmer and P. L. B. Oxley, “Mechanics of orthogonal machining,” Proceedings of the Institution of Mechanical Engineers, vol. 173, no. 1, pp. 623–654, 1959.
[17] E. Muthu, K. Senthamarai, and S. Jayaba, Finite element simulation of machining a nickel-based superalloy: Inconel 718,” International Journal of Advanced Engineering Applications, vol. 5, no. 3, pp. 22-27, 2012.
[18] V. Veeranaath, A. Anshuman, and S. Sethia, “Experimental Study and Finite Element Analysis of the Impact of Tool Edge Geometry in Orthogonal Machining of Super Alloy Inconel 718,” in IOP Conference Series: Materials Science and Engineering, vol. 912, no. 3, p. 032032, IOP Publishing, 2020.
[19] G. C. Mouli, K. P. Marimuthu, and T. Jagadeesha, “2d finite element analysis of inconel 718 under turning processes,” in IOP Conference Series: Materials Science and Engineering, vol. 912, no. 3, p. 032021, IOP Publishing, 2020.
[20] U. M. R. Paturi, S. Methuku, S. S. Siripragada, Y. Sangishetty, and R. K. Gunda, “Finite element simulations of machinability parameters in turning of Inconel 718,” Materials Today: Proceedings, vol. 38, pp. 2658–2663, 2021.
[21] Y. Liu, D. Xu, M. Agmell et al., “Numerical and experimental investigation of tool geometry effect on residual stresses in orthogonal machining of Inconel 718,” Simulation Modelling Practice and Theory, vol. 106, p. 102187, 2021.
[22] B. Peng, T. Bergs, F. Klocke, and B. Döbbeler, “An advanced FE modeling approach to improve the prediction in machining difficult-to-cut material,” The International Journal of Advanced Manufacturing Technology, vol. 103, pp. 2183–2196, 2019.
[23] A. F. V. Pedroso, V. F. C. Sousa, N. P. V. Sebbe et al., “A brief review of INCONEL® alloys numerical analysis on predictability,” Procedia Computer Science, vol. 232, pp. 1109–1120, 2024.
[24] T. Jadam, S. Datta, and M. Masanta, “Influence of cutting tool material on machinability of Inconel 718 superalloy,” Machining Science and Technology, vol. 25, no. 3, pp. 349–397, 2021.
[25] Y. Zhang and J. Zheng, “Modelling and Finite Element Simulation of Ball-End Milling for Nickel-Based Superalloy Inconel 718,” in International Conference on Advances in Construction Machinery and Vehicle Engineering, Singapore: Springer Nature Singapore, pp. 889–899, 2023.
[26] M. R. U. Rahim and P. K. Bharti, “Energy absorption characteristics of thin-walled sinusoidal corrugated tube using RSM-CCD,” Production Engineering Archives, vol. 26, no. 4, pp. 144–153, 2020.
[27] M. R. U. Rahim and P. K. Bharti, “Buckling analysis of innovative corrugated column by using response surface methodology,” Acta Marisiensis. Seria Technologica, vol. 18, no. 2, pp. 8-17, 2020.
[28] M. R. U. Rahim, M. F. Hasan, and M. N. Khan, “Optimization of square-based tapered twisted hollow tube using CCD approach in RSM,” Frontiers in Engineering and Built Environment, vol. 5, no. 3, pp. 209–226, 2025.
[29] A. Thakur and S. Gangopadhyay, “State-of-the-art in surface integrity in machining of nickel-based super alloys,” International Journal of Machine Tools and Manufacture, vol. 100, pp. 25–54, 2016.
[30] R. S. Pawade, S. S. Joshi, and P. K. Brahmankar, “Effect of machining parameters and cutting-edge geometry on surface integrity of high-speed turned Inconel 718,” International Journal of Machine Tools and Manufacture, vol. 48, no. 1, pp. 15–28, 2008.
[31] P. J. Arrazola, T. Özel, D. Umbrello, M. Davies, and I. S. Jawahir, “Recent advances in modelling of metal machining processes,” CIRP Annals, vol. 62, no. 2, pp. 695–718, 2013.
[32] E. O. Ezugwu and Z. M. Wang, “Titanium alloys and their machinability—a review,” Journal of Materials Processing Technology, vol. 68, no. 3, pp. 262–274, 1997.
[33] T. Özel and D. Ulutan, “Prediction of machining induced residual stresses in turning of titanium and nickel-based alloys with experiments and finite element simulations,” CIRP Annals, vol. 61, no. 1, pp. 547–550, 2012.
[34] D. A. Stephenson and J. S. Agapiou, Metal cutting theory and practice, CRC Press, 2018.
[35] F. Jafarian, D. Umbrello, and B. Jabbaripour, “Identification of new material model for machining simulation of Inconel 718 alloy and the effect of tool edge geometry on microstructure changes,” Simulation Modelling Practice and Theory, vol. 66, pp. 273–284, 2016.
[36] P. J. Arrazola, “Investigations on the effects of friction modeling in finite element simulation of machining,” International Journal of Mechanical Sciences, vol. 52, no. 1, pp. 31–42, 2010.
[37] S. Pervaiz, A. Rashid, I. Deiab, and M. Nicolescu, “Influence of tool materials on machinability of titanium-and nickel-based alloys: a review,” Materials and Manufacturing Processes, vol. 29, no. 3, pp. 219–252, 2014.
[38] E. O. Ezugwu, “Key improvements in the machining of difficult-to-cut aerospace superalloys,” International Journal of Machine Tools and Manufacture, vol. 45, no. 12-13, pp. 1353–1367, 2005.
[39] T. Kitagawa, A. Kubo, and K. Maekawa, “Temperature and wear of cutting tools in high-speed machining of Inconel 718 and Ti 6Al 6V 2Sn,” Wear, vol. 202, no. 2, pp. 142–148, 1997.
[40] G. R. Johnson, “A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures,” in Proceedings of the 7th International Symposium on Ballistics, Netherlands, pp. 541–547, 1983.
Downloads
Published
Issue
Section
License
Copyright (c) 2026 The Author(s)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
