Finite Element Modeling of Machining Nickel Superalloy Produced By Direct Energy Deposition Process

Abstract Direct Energy Deposition (DLD) is a generative manufacturing method for metals and it is usually employed to build near-net-shape components starting from powder, through a layer-by-layer production strategy. This process provides an opportunity to fabricate complex shaped and functionally parts mainly used in high performance engineering areas, such as aerospace and automotive industry. However, the metal parts produced frequently do not satisfy the tolerances as well as the surface quality, therefore the post-process finishing operations as machining are normally considered as a valid solution to satisfy the geometrical requirements. During the design phase, the finite element simulation results a fundamental tool to help the engineers in the correct decision of the most suitable process parameters, especially in manufacturing processes, in order to produce products of high quality. The aim of this work is to develop a 3D finite element model of turning operation of Nickel Superalloy Inconel718, produced via Direct Energy Deposition (DLD). A customized user sub-routine was built-up in order to model the mechanical behavior under machining operations of as deposited condition to predict the main fundamental variables as cutting forces and temperature.