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Machining process simulation is an important aspect in the manufacturing context that generates a scenario to enhance the process performance in terms of time and cost. With unique high temperature and stress properties and applications of Inconel 718 material in various sectors of engineering, the machinability assessment has become an important issue which needs a detailed investigation. The present work has been attempted to study and compare experimental results with simulation results based on finite element approach in dry milling of Inconel 718 with coated carbide inserts. During machining of Inconel 718, cutting tool environment reaches very high localized temperatures and high stresses due to repeated impact loads during interrupted cutting. The milling tests were conducted under various cutting conditions to investigate their effect on the response parameters. A simulation model based on finite element approach is proposed using DEFORM 3D to investigate cutting forces in end milling operation. The simulation results are validated with the experimental trials. An average error of 7% is obtained in the response function.

FEA Based Simulation and Experimental Analysis of Forces in Dry Milling of Inconel 718