Finite Element Modeling and Cutting Simulation of Inconel 718

Segmented chips are often found in high-speed-cutting. This type of chip formation can be traced back to adiabatic shear bands. The reference workpiece material is the Nickel-based alloy Inconel 718, which shows an affinity to segmented chip formation. A realistic simulation of the chip formation and of the related cutting forces and chip temperatures serve to better process understanding. By implementing a material model into the FE-simulation which besides strain, strain rate and temperature includes ductile damage, a realistic description of the material behavior becomes possible. The results of the experiments and of the 2D- and 3D-simulations correlate well.