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Influence of Cutting Parameters on Tool Temperatures and Residual Stresses in Machining Aerospace Alloys: A DEFORM 3D Simulation Approach

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Abstract:

This study investigates the influence of cutting parameters on tool temperatures and residual stresses during the machining of aerospace alloys Inconel-718, Hastelloy-X, and Ti6Al4V. Experimental turning operations were conducted under predetermined cutting speeds, feed rates, and cutting depths, followed by residual stress measurements using X-ray diffraction (XRD). Maximum tool temperatures were recorded using a thermal camera. Additionally, numerical simulations were performed using DEFORM 3D under identical cutting conditions to validate the experimental findings. The results reveal that Hastelloy-X exhibited the highest residual stresses and cutting tool temperatures, while Ti6Al4V showed the lowest. A close agreement was observed between the experimental and simulation data, highlighting the accuracy of the DEFORM 3D model. This study provides a comprehensive analysis of Hastelloy-X, a material with limited prior research, contributing novel insights into its machining characteristics. The findings will aid in optimizing cutting parameters for improved performance and tool life in aerospace applications.

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Advanced Engineering Forum Vol. 54 View Preview

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Periodical:

Advanced Engineering Forum (Volume 54)

Pages:

19-28

DOI:

https://doi.org/10.4028/p-2KlBaN

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Online since:

January 2025

Authors:

Mehmet Alper Sofuoğlu*, Gökhan Haydarlar, Mesut Tekkalmaz

Keywords:

Cutting Tool Temperature, High-Temperature Alloy, Machining Parameters, Numerical Simulation (DEFORM), Residual Stress Analysis

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© 2025 Trans Tech Publications Ltd. All Rights Reserved

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