Sensitivity Analysis of Tool-Chip Contact Parameters when Predicting Residual Stresses in Turning of Inconel 718

Heat-resistant alloys like Inconel 718 are used in critical components such as aircraft engine turbine discs. Due to the extreme thermo-mechanical solicitations that must suffer during their lifetime, reliability is essential, even more if its failure could lead to loss of human lives. Surface integrity is a critical issue in this kind of components and especially residual stresses are a key aspect. Currently, the development and optimization of the machining process with regards to the residual stresses is done through expensive experimental trial and error methods. This article shows the research work made on the simulation of a machining model in three dimensions with the Deform (TM) commercial program. The results obtained show the influence of contact parameters (friction coefficient, heat transfer coefficient) not only on the cutting forces and temperatures, but also in the generation of residual stresses.