Investigation of friction models in the machining of Inconel 625 Super Alloy using FEM

Simulation of metal cutting by Finite Element Method largely depends on material model and friction model. Inconel 625 is one of the super alloys, which has numerous applications but has no specific material model and friction model for simulating metal cutting. The Inconel 625 has a behaviour of softening at higher strain and strain rates. Material models that are already available do not represent this behaviour of Inconel 625. This paper follows the modified Johnson-Cook material model suggested by Hokka to obtain the flow stress data. Parameters like Cutting force, Temperature at tool chip interface, Tool Wear can be used to evaluate the effectiveness of friction model by comparing those obtained experimentally with the simulation results. In this paper, the Cutting forces are considered for evaluation of friction model. Cutting forces obtained experimentally by the turning of Inconel 625 rod with TiN tool insert. Simulation of the turning of Inconel 625 is done in DEFORM 3D software. Coulomb Friction model and Shear Friction model are the two friction models taken for investigation in this paper. Simulation is carried out by applying the two friction models and the actual process parameters. On comparison with the experimental results, Shear Friction model is found to be more accurate than the coulomb friction model for Inconel 625.