Simulation Modelling Practice and Theory 40 (2014) 192207

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Simulation Modelling Practice and Theory

journal homepage: www.elsevier.com/locate/simpat

Theoretical predictions and experimental validations

on machining the Nimonic C-263 super alloy
C. Ezilarasan a, V.S. Senthil kumar a,, A. Velayudham b
a
Department of Mechanical Engineering, College of Engineering, Anna University, Chennai 25, India
b
CVRDE, Avadi, Chennai 54, India

a r t i c l e i n f o a b s t r a c t

Article history: The current paper presents the simulated 3D Finite Element Model (FEM) and experimen-
Received 10 April 2013 tal validation while turning the Nimonic C-263 super alloy using a cemented carbide cut-
Received in revised form 21 September 2013 ting tool. FEM machining simulations was carried out using a Lagrangian nite element
Accepted 23 September 2013
based machining model to predict the tangential cutting force, temperature distribution
Available online 8 November 2013
at tool tip and the effective stress and strain. All simulations were performed according
to the cutting conditions designed, using the orthogonal array. The work piece was consid-
Keywords:
ered as perfectly plastic and its shape was taken as a curved model. An experimental val-
Simulation
Nimonic C-263 alloy
idation of the cutting process was conducted in order to verify the simulated results of
Cutting force tangential cutting force and temperature at tool tip and the comparison shows that the
Cutting temperature percentage error 6% was observed and the shear friction factor 0.6 indicates good agree-
Effective stress and strain ment between the simulated results and the experiment results. As the cutting speed is
increased from 22 m/min to 54 m/min at higher feed rate, a larger strain to an extent of
up to 6.55 mm/mm, a maximum value of 810 MPa stress and higher temperature localiza-
tion to an extent of 620 C at tool tip were observed.
2013 Elsevier B.V. All rights reserved.

1. Introduction

Great advances are taking place in the development and application of newer materials, more specically in aero engines,
to enhance the thrust-to-weight ratio and to meet the requirement of sustaining the corresponding increase in temperature
in the combustion area. To meet this demand, the Nimonic C-263 super alloy is currently being applied in the combustion
area of gas turbines, due to its unique resistance to thermal fatigue and creep characteristics, by the presence of higher cobalt
content, unlike the Inconel 718 super alloy wherein iron is used instead. The Presence of the cobalt and carbide forming ele-
ments like Molybdneum, Tungsten, Niobium, etc. in the nickel based super alloys makes them more creep and heat resistant,
but also pose challenges to cutting tool manufacturers and machine tool builders. Machining techniques for super alloys
should, therefore, be adopted specic to the material characteristics.
Any variation in the process will impair the quality and reliable performance of the products, which is the most serious
concern in the case of aerospace manufacturing processes. To predict the machining characteristics of complex materials in
advance and reduce the cost of manufacture resulting due to improper machining, suitable modeling techniques are called
for. Modeling is one of the widely used tools in the study of machining processes due to its several advantages in the area of
design, validation and control of the machining process [1]. The numerical simulation in machining instead of the experi-
mentation is very much useful to predict both mechanical and thermal behavior of both the material and tool without

Corresponding author. Tel.: +91 9444952438.

E-mail addresses: ezhilshriram.c@gmail.com (C. Ezilarasan), vsskumar@annauniv.edu (V.S. Senthil kumar).

1569-190X/$ - see front matter 2013 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.simpat.2013.09.008
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 193

spending time and money with experimental work. The accuracy of the simulated results mainly depends on the input val-
ues. Therefore, it is importance to understand how the input data affects the prediction of the simulated results and the pre-
dictive models of machining processes are useful to forecast and evaluate machining performance indicators such as chip
formation, cutting force, cutting temperature, tool wear and surface nish [2]. Vaz et al. [3] stated that modeling of metal
cutting is complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/fric-
tion and material failure and the numerical simulation of machining to be a challenge to existing algorithms and computa-
tional tools. The large and localized plastic deformation and complex contact conditions are some of the difculties
associated with modeling of machining process using FEA.
Of the modeling techniques Finite Element Modeling is currently most widely applied in the machining area, due to the
progress in the eld of software computing. During machining, the interaction between the work piece and the cutting tool is
very complex and highly stochastic, because of the physical phenomena that are taking place from micro to macroscale. In
addition, several variables, viz. the properties and condition of the work material, tool material, tool geometry, cutting
parameters, the dynamic performances of the machine tool and clamping conditions are also interlinked. Analysis and con-
trol are therefore difcult tasks in any machining process, but modeling can provide the right solution to this. Of the char-
acteristics, cutting force and temperature play a vital role in dictating the performance of the machined surface of the work
materials. Thus, in the present paper FEM is used as a modeling tool to predict the cutting force and temperature through
simulation. The simulated model is then used to validate the experimental data that were obtained during turning.
The Finite Element Method (FEM) permits the prediction of the cutting forces, stresses, tool wear, and temperatures of the
cutting process, so that the cutting tool can be designed. With this method the best cutting parameters are determined. How-
ever, the accuracy of the obtained results with the nite element methods depends mainly on the accuracy of the input val-
ues, so it is of extreme importance to understand how the input data affects the prediction of the Finite Element Models
(FEMs) analysis. Also, accurate physical, mechanical and thermal modeling of deformation and solidication behavior and
the interface conditions are essential, for the optimal use of these advanced models for industrial applications, which tend
to be difcult in formulation [4].
Maranhao and Paulo Davim [5] determined the inuence of the friction coefcient in the tool-chip interface on cutting
and feed forces, cutting temperature, plastic strain, plastic strain rate, maximum shear stress and residual stresses when
machining a stainless steel (AISI 316). Further, they conducted experimental validation of the cutting process to verify
the numerical simulated results. The comparison has shown that the friction modeling at the tool-chip interface has a sig-
nicant inuence on the results. Finally, they concluded that the friction coefcient greatly inuences the cutting and feed
forces, cutting power, maximum cutting temperature and plastic strain and the friction coefcient cannot be measured with
precision and it needs to be iterated.
There are two types of nite element formulations to describe a continuous medium: Lagrangian and Eulerian. The
Lagrangian is widely used. In the Lagrangian analysis, the mesh grid deforms with the material, while in the Eulerian analysis
the grid is xed in space [6]. Lagrangian formulation with continuous remeshing has been used in the simulation of contin-
uous and segmented chip formation in machining processes [7]. The right choice of the nite element software is very
important in determining the scope and quality of the analysis that will be performed. The most important software codes
used for the simulation of metal cutting are: the ABAQUS, DEFORM and AdvantEdge. In this study, DEFORM 3D software,
based on the implicit Lagrangian computational routine with continuous adaptive remeshing is used for the FEM simulation.
Grzesik et al. [8] created a FEM simulation model to obtain numerical solutions of the cutting forces, specic cutting en-
ergy and adequate temperatures occurring at different points through the chip/tool contact region and the coating/substrate
boundary for a range of coated tool materials and dened cutting conditions. The various thermal simulation results ob-
tained were compared with the measurements of the average interfacial temperature and discussed in terms of various lit-
erature data.
The modeling and analysis of the machining parameters in orthogonal cutting using the nite element method (FEM) be-
comes cost effective and economic [9]. Sool et al. [10] developed a 3D Finite Element Model to simulate the turning of the
Inconel 718 super alloy, using the ABAQUS/Explicit. The generation of cutting forces, temperature and stress distributions
along with chip ow were predicted in machining aluminum alloy using DEFORM 3D [11]. The segmented chips were found
in high speed machining of super alloy Inconel 718. The type of chips formation, a realistic simulation of the chip formation
and of related cutting forces and chip temperature serve to better process understanding. The simulated results correlate
well with experimental results [12].
Maurel-Pantel et al. [13] developed a FEA model using commercial software LS-Dyna to to perform simulations of shoul-
der milling operations on AISI 304L stainless steel. The material behavior was modeled with a JohnsonCook law. They re-
ported that proposed model was able to accurately describe the cutting forces curves for a shoulder milling operation
according to the rigid tool assumption. Jalili Saffar et al. [14] presented a 3D simulation system to predict cutting forces
and tool deection during end-milling operation. The material behavior was modeled with a JohnsonCook law. The accu-
racy of 3D simulation, results (cutting forces and tool deection) were the theoretical relationships, in terms of agreement
with experiments. The concluded that the simulation is capable of predicting the cutting forces and tool deection.
Hendri et al. [15] developed a 3D Finite Element Model using DEFORM 3D to study the effect of the rake angle on the
cutting force, stress, strain and temperature of the edge of the carbide cutting tool in the orthogonal machining process.
Yahya Dogu et al. [16] developed a thermal model to study the temperature distribution in orthogonal cutting, using the
nite element method, in which the model estimates the temperature as a function of heat generation. Tugrul Ozel [17]
194 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

presented experimental and 3D nite element simulations using DEFORM 3D to predict the chip formation, cutting forces,
temperatures, stresses and tool wear on uniform and variable edge microgeometry tools. Abdullah Kurt et al. [18] have
investigated the effect of chamfer angle in machining AISI 52100 bearing steel using ANSYS software, in which the FEA re-
sults indicates that the chamfer angle has inuence on cutting force and tool stress. Jialong Rea et al. [19] have created a FEA
model using DEFORM 3D software on machining Inconel 718, in which the FEA model results identify the effect of machining
parameters on cutting force and cutting temperature.
Munoz-Sanchez et al. [20] stated that the Finite Element Analysis (FEA) is a powerful tool used to simulate cutting pro-
cesses, allowing the analysis of different parameters inuent on machining induced residual stresses. They developed a FEA
model using the commercial code ABAQUS by changing the tool geometry to predict machining induced residual stresses in
AISI 316 L and a reasonable agreement with the experimental results was observed. Paulo Davim [21] studied the thermal
and mechanical behavior in machining of aluminum alloys (Al 7075-0) using PCD (polycrystalline diamond) and K10 (ce-
mented carbide) tools with help of commercial nite element software Advantage. They have simulated the cutting forces,
temperature, pressure, von Mises stress, maximum shear stress, plastic strain, and plastic strain rate. They concluded that
polycrystalline tool has a superior performance in terms of cutting and feed forces and temperature when compared to
the cemented carbide tool.
From the literature it was found that for materials difcult to cut, like the nickel based Nimonic C-263 alloy, it is crucial to
know the mechanical and thermal load acting on the cutting insert under changing cutting parameters. The FEM method
turns out to be a suitable tool to know the condition of the cutting tool, in term of forces, temperatures and chip morphology.
Thus the main objective of this research is to provide a powerful analytic tool to model and validate the cutting process. The
Finite Element Model was carried out in turning the Nimonic C-263 alloy to predict the responses such as tangential cutting
force, temperature distribution at tool tip, effective stress and strain with the help of DEFORM 3D software. A Turning oper-
ation using a coated cemented carbide insert has been considered, to study the machining behavior of the Nimonic C-263
super alloy and to compare the simulated results with experimental results.

2. Process setup and conditions

Before modeling and simulation, the initial data, namely, the process parameters and conditions, work and cutting tool
material properties, cutting speed, depth of cut, feed rate, environment temperature, other assumptions, etc. are to be loaded
as input. These parameters will be described and set up in the rst step, pre-processor. The process conditions are given in
Table 1.
The work piece is considered as perfectly plastic and its shape is taken as a curved model having a length 20 mm, which is
shown in Fig. 1. The material is modeled by the JohnsonCook (JC) material model as shown in Eq. (1). This JC model is suit-
able for modeling materials, which have high strain, strain rate, strain hardening and non-linear material properties.
    m 
p_ h  hR
r A Bpn C ln _ 1 1
e0 hm  hR
where r is the ow stress, p is the plastic equivalent strain, p_ is the plastic strain rate, hm is the melting temperature, hR is the
initial temperature, total strain, the total strain rate, and the material parameter values are: Coefcient A is the yield strength
(MPa), B is the hardening modulus (MPa) and C is the strain rate sensitivity coefcient, n is the hardening coefcient and m
the thermal softening coefcient. The values of these parameters are given as follows: A-450 MPa, B-1700 MPa, C-0.017, n-
0.65, m-1.3 and Tm-1628 K [22]. As the properties of the Nimonic C-263 were not dened in the material library of DEFORM
3D, the thermo mechanical properties given in Table 2 are fed as input to dene the work material. The basic assumption
made in this FEM analysis is shown in Table 3.
The friction along the tool and chip contact during the machining process is a complex and it is inuenced by the chip
geometry, built edge formation, cutting temperature and tool wear. The friction between the chip and tool constitute com-
plex aspects of metal cutting process [3]. The friction coefcient may be specied as a constant, a function of time, or a func-
tion of interface pressure. The shear friction factor values in the range of 0.50.6 give reasonable results. The frictional force
in the Coulomb law model is dened as in the following equation:
fs lp 2

Table 1
Process conditions and their levels.

S. no. Conditions Unit Symbols L1 L2 L3

1 Speed m/min V 22 33 54
2 Feed rate mm/rev S 0.051 0.102 0.143
3 Depth of cut mm ap 0.50 0.75 1
4 Machining environment Dry
5 Ambient temperature 20 C
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 195

Fig. 1. Dening the work piece shape.

Table 2
Thermo-mechanical properties of the Nimonic C263 alloy.

S. no. Thermo-mechanical properties Values Unit

1 Density 8360 kg/m3
2 Youngs modulus at 20 C 224 GPa
3 Poissons ratio 0.3
4 Thermal conductivity 11.72 W/(m K)
5 Heat capacity 0.461 J/g C
6 Specic heat 461 J/kg C

Table 3
Basic assumptions made in this FEM analysis.

S. no. Assumptions Values

1 Shear friction factor 0.6
2 Element type Tetrahedral
3 Mesh type Fine mesh
4 Node 10 nodes
5 Relative mesh type (tool) 40,000
6 Relative mesh type (work) 40,000
7 Workpiece material Nimonic C-263
8 Work material type Plastic, isotropic
9 Work piece shape Curved model
10 Tool material Carbide insert
11 Coolant Not used
12 Environment temperature 20 C
13 Convection coefcient 0.02
14 Heat transfer coefcient 45
15 Number of simulation steps 1000
16 Step increment to save 25
17 Arc angle to cut 20

where fs is the frictional stress, p is the interface pressure between two bodies and is the friction factor [23]. The shear fric-
tion factor values in the range of 0.4, 0.5 and 0.6 were used to predict the cutting force and temperature at tool tip and the
simulated results (by considering shear friction factor of 0.4, 0.5 and 0.6) were compared with the experimental results. The
shear friction factor 0.6 indicates good agreement between the simulated results and the experiment results.
The 3D model of the cutting insert was drawn using the Solid works CAD package and exported in the STL format into the
DEFORM 3D package. The solid model of the insert is shown in Fig. 2. The cutting tool material is considered as tungsten
carbide (WC) and modeled as a perfectly rigid body. Fig. 3 shows an isometric view of the initial tool/work piece mesh con-
guration, where +Y is the cutting direction, X is the feed direction and Z is the depth of cut direction. Fig. 4 shows the
undeformed and deformed work piece mesh. In this study, DEFORM 3D computational modeling is utilized to study the ef-
fect of the machining parameters on the cutting force, and cutting temperature at the tool end. All simulations were per-
formed according to the cutting conditions designed, using an orthogonal array.
196 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

Fig. 2. Solid model of the insert.

Fig. 3. Isometric view of the initial tool/work piece mesh generation.

3. Experimental details for validation

Cutting experiments were conducted to validate the three-dimensional FE model. The Nimonic C-263 super alloy solution
treated to a hardness of 3234 HRc and having a composition of 52.49 Ni, 0.19 Si, 0.46 Mn, 20 Cr, 6.29 Mo, 0.07 Cu, 1.0 Fe,
16.7 Co, 1.94 Ti, 0.48 Al, 0.04 Nb, 0.15 W, 0.02 V, 0.02 C, 0.001 S, 0.007 Ta, was used as the work material for the turning trials.
The selected cutting tool was Sandvik Coromant make, PVD TiAlN coated cemented carbide ISO inserts to CNMX 1204 A1-SM
of S grade having excellent adhesion on a hard, ne-grained substrate with 6% Co for high hot hardness and good resistance
against plastic deformation and ank wear. The insert is of negative geometry having (6) back and side rake angle and
having the following properties: Thermal conductivity: 4.63 W/m K, Youngs modulus: 348GPa, Poissons ratio: 0.25 and
Emissivity: 0.07. The insert was xed on the ISO tool holder PCLNR 2020 K12 of Sandvik Coromant make, and machining
trials were conducted on a center lathe having sufcient spindle power under a dry machining environment. Taguchis de-
sign of experiment with a standard L27 orthogonal array was selected for conducting the experiments. The cutting forces gen-
erated during machining were measured using a three-component Kistler (Model 9257B) piezo-electric tool post
dynamometer. To measure the cutting temperature to the nearest possible cutting edge, the tool holder was modied by
drilling a hole, 1.5 mm away from the cutting edge of the insert and the temperature was measured using alumel/chromel
thermocouple which has a measuring capacity of 1000 C. The temperature measurement set up is shown in Fig. 5. The error
between the experimental values and the model predicted values are computed using the following expression:
X fem  X exp 
Percentage of error  100 3
X exp

where Xexp is the experimental value and Xfem is the FEM simulated value.
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 197

(a) Undeformed mesh

(b) Deformed mesh

Fig. 4. (a and b) Work piece mesh in turning process.

Fig. 5. Temperature measurement setup.

4. Results and discussion

4.1. Cutting force simulation and validation

The coded values of the machining parameters, actual setting values, FEM predicted outputs and experimental results are
given in Table 4. The comparison of the simulated tangential force and experimental values for the generation of the tangential
198 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

Table 4
Experimental conditions and results.

Experiment number V (m/min) S (mm/rev) ap (mm) Experimental outputs FEM model predicted outputs
Fy (N) H (C) Fy (N) H (C) Stress (MPa) Strain (mm/mm)
1 22 0.05 0.50 340 300 398 325 375 3.100
2 22 0.05 0.75 420 320 425 340 405 3.250
3 22 0.05 1 470 340 455 365 435 3.750
4 22 0.102 0.50 400 385 435 370 500 4.050
5 22 0.102 0.75 435 415 455 390 520 4.225
6 22 0.102 1 450 440 465 465 575 4.350
7 22 0.143 0.50 542 465 580 490 620 4.650
8 22 0.143 0.75 560 485 585 510 630 4.750
9 22 0.143 1 585 500 662 540 645 4.925
10 33 0.05 0.50 320 375 365 410 400 3.575
11 33 0.05 0.75 385 420 410 430 425 3.725
12 33 0.05 1 410 435 425 440 480 3.825
13 33 0.102 0.50 425 475 430 510 600 4.700
14 33 0.102 0.75 415 510 425 545 630 4.925
15 33 0.102 1 445 530 460 550 690 5.200
16 33 0.143 0.50 475 545 495 585 700 5.420
17 33 0.143 0.75 510 555 520 570 720 5.350
18 33 0.143 1 475 575 495 610 730 5.575
19 54 0.05 0.50 395 465 410 485 590 4.750
20 54 0.05 0.75 386 490 415 510 610 4.600
21 54 0.05 1 385 510 395 535 650 4.800
22 54 0.102 0.50 420 520 415 545 690 5.100
23 54 0.102 0.75 440 540 445 555 720 5.400
24 54 0.102 1 400 560 391 575 750 5.725
25 54 0.143 0.50 442 565 455 590 785 6.125
26 54 0.143 0.75 420 585 435 620 790 6.250
27 54 0.143 1 438 600 450 610 810 6.550

cutting force is illustrated in Fig. 6. From Fig. 6, it can be seen that the predicted values are closer to the experimental values.
Further, from Fig. 7, the percentage error computed between the experimental and FEM predicted values ranges almost within
6% except at experiments No. 1, 9 and 10, which clearly indicates the close correlation between the FEM model and the
experiment; thus the simulated FEM can be used effectively for predicting the tangential cutting force while turning the
Nimonic C-263 super alloy. To determine the simulated tangential cutting force, the average force was considered as shown

700
Cutting force (N)

Fy-Experimental value
600 Fy-Predicted thro FEM model
500

400

300
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Experiment Number

Fig. 6. Comparison of the measured and simulated cutting forces.

15

12
Percentage error

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number

Fig. 7. Percentage error between the experimental and predicted values for the cutting force.
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 199

in the Fig. 8(aj) [12]. Fig. 8(aj) illustrates the few output of the tangential cutting force generated during the FEM simulation
under different cutting conditions and shear friction factors. The shear friction factor 0.6 indicates good agreement between
the simulated cutting force and the experiment results. However, the simulated cutting force generated by considering the
shear friction factors 0.4 and 0.5 does not correlate with the experimental results, which is evidently shown in Fig. 8(gj).
The mesh size was inuenced on the force output uctuations and smaller uctuation in the force output was observed
with ne mesh compared to the analysis with coarse mesh. It is concluded the ne mesh size on the work piece to be found
out to simulate a force output without too large uctuation [24]. The relative mesh is considered for both tool and work piece
to model the tool and work piece by considering the size ratio 5. The relative mesh values in the range of 30,000, 35,000 and
40,000 were used to predict the cutting force and temperature at tool tip and the simulated results (by considering relative
mesh value of 30,000, 35,000 and 40,000) were compared with the experimental results. The relative mesh 40,000 indicates
good agreement between the simulated and the experiment results and the typical simulated force output uctuation is
shown in Fig. 8(aj).

(a) V- min 22m/, S-0.05mm/rev, ap-0.5mm (b) V-22m/min, S-0.102mm/rev, ap -0.5mm

Shear friction factor = 0.6 Shear friction factor = 0.6

(c) V-22m/min, S -0.102mm/rev, ap -1mm (d) V-22m/min, S -0.143mm/rev, ap -1mm

Shear friction factor = 0.6 Shear friction factor = 0.6

(e) V-33m/min, S -0.102mm/rev, ap -1mm (f) V-54m/min, S -0.143mm/rev, ap -1mm

Shear friction factor = 0.6 Shear friction factor = 0.6
Fig. 8. (aj) Generated main cutting force during FEM simulations at different cutting conditions and shear friction factors.
200 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

(g) V-22m/min, S-0.05mm/rev, ap-0.5mm (h) V-22m/min, S-0.05mm/rev, ap-0.5mm

Shear friction factor = 0.4 Shear friction factor = 0.5

(i) V-54m/min, S -0.143mm/rev, ap -1mm (j) V-54m/min, S -0.143mm/rev, ap -1mm

Shear friction factor = 0.4 Shear friction factor = 0.5
Fig. 8 (continued)

The DEFORM solves time dependent non-linear problems by generating a series of FEM solutions at discrete time incre-
ments. At each time increment, the velocities, temperatures, and other variables of each node in the nite element mesh are
determined based on thermo mechanical properties of the work piece materials. The length of this time step, and number of
steps simulated, are determined based on specifying the step controls such as starting step number, number of simulation
steps and step increment to save [23]. In this paper, starting step number is set as 1, number of simulation steps is given as
1000 and step increment to save is given as 20. The tangential cutting force was uctuating in the transient simulations and
remained steady above 600 simulation steps. From the illustrations, it is seen that the tangential cutting force varies between
390 N and 672 N depending upon the cutting conditions. From Fig. 8(af), an increase in the tangential cutting force could be
seen with an increase in the feed rate. But with a higher depth of cut (1 mm), a steep increase in the tangential cutting force
to an extent of 672 N, is observed, with an increase in the feed rate (Fig. 8(c) and (d)), which could be attributed to the gen-
eration of a higher order chip load at a higher combination of feed and depth of cut. This steep increase in the tangential
cutting force from 478 N to 672 N corresponding to the feed rates of 0.102 mm/rev to 0.143 mm/rev, identies the feed rate
of 0.102 mm/rev as the critical feed rate for turning the Nimonic C-263 alloy. However, with an increase in the cutting speed,
a reduction in the tangential cutting force is seen, which could be attributed to the thermal softening of the material at a
higher cutting speed.

4.2. Simulation and experimental validation of cutting temperature

The cutting temperature in machining is important, since it is the dominating factor for tool life, part quality, chip mor-
phology, etc.; thus, there is a great deal of research is going on in the measurement of cutting temperatures while machining.
Very high tool temperatures are experienced when machining the Nimonic C 263 alloy, due to the low value of (kqC). Nimon-
ic C-263 has a low thermal conductivity of 11.72 W/m C, and specic heat (461 J/kg C). When different materials are ma-
chined with the same tool, cutting uid and feed rate, the temperature generated will be as per the following equation [25].
 1
Vt 2
hT  u 4
kqC

where h is the mean tool face temperature; u is the specic cutting energy; V is the cutting speed; t is the undeformed chip
thickness; k is the thermal conductivity of work and qC is the volume specic heat of work.
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 201

Apart from tool wear, the generation of temperature also affects the subsurface of the machined surface, which is more
detrimental and of greater concern, especially in the case of aerospace materials. Therefore, it is essential to investigate the
generation of cutting temperature while machining. Fig. 9 shows the three dimensional view of the insert and work piece
during FEM simulation using DEFORM software. The prediction of cutting temperature using FEM model and measured tem-
perature at the tip of the cutting insert during experimentation is compared in Fig. 10. The percentage error between the
experimental and predicted values through the FEM model ranges almost around 6% percentage, except at few cases where
the percentage error is around 8% as shown in the Fig. 11. From illustrations 10 and 11, it can be seen that the predicted
values are closer to the experimental values thus the simulated model can be used as reference for limiting the cutting con-
ditions within which the Nimonic C-263 super alloy can be machined with controlled tool temperature. This would also help
in selecting the right tool material based on its hot hardness property while machining Nimonic C-263 material.
Fig. 12(ae) illustrates the few output of the temperature distribution at the tool tip during the FEM simulation under
different cutting conditions and shear friction factors. The shear friction factor 0.6 indicates good agreement between the

Fig. 9. 3D view of insert and work piece during simulation.

Temperature at tool tip (C)

700

600

500

400

300

200
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experimental Number

Fig. 10. Comparison of measured and simulated temperature at tool tip.

10

8
Percentage error

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26
Experiment Number

Fig. 11. Percentage error between the experimental and the predicted values for temperature at tool tip.
202 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

(a) V-22 m/min, S-0.102 mm/rev, ap-0.50 mm

Shear friction factor = 0.6

(b) V-33m/min, S-0.102mm/rev and ap-0.75mm

Shear friction factor = 0.6

(c) V-54m/min, S-0.143mm/rev and ap -1mm

Shear friction factor = 0.6

(d) V-54m/min, S -0.143mm/rev, ap -1mm

Shear friction factor 0.4

(e) V-22 m/min, S-0.102 mm/rev, a p-0.50 mm

Fig. 12. (ae) Simulated temperature distributions at tool tip for different cutting conditions and shear friction factor.
C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 203

(a) Effective stress distributions at

V - 22 m/min, S- 0.102 mm/rev, ap - 0.75 mm

(b) Effective stress distributions at

V - 33 m/min, S - 0.102 mm/rev, ap - 0.75 mm

(c)
Fig. 13. (ac) Effective stress distributions at different cutting conditions.
204 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

(a) Effective strain distributions at

V - 22 m/min, S - 0.102 mm/rev, ap - 0.75 mm

(b) Effective strain distributions at

V - 33 m/min, S- 0.102 mm/rev, ap - 0.75 mm

(c) Effective strain distributions at

V - 54 m/min, S - 0.102 mm/rev, ap - 0.75 mm
Fig. 14. (ac) Effective strain distributions at different cutting conditions.
 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207 205

simulated temperature distribution at the tool tip and the experiment results. However, the simulated values by considering
the shear friction factors 0.4 and 0.5 does not correlate with the experimental results, which is evidently shown in Fig. 12(d
and e). The temperature at the tip of the insert varies depending on the level of the machining parameters, in which it is
observed that the temperature generation at the tool tip increases with increase in the cutting speed, feed rate and depth
of cut. From the illustrations, it is seen that the highest cutting temperature occurred at the end of the cutting edge to an
extent of 610 C at a combination of 54 m/min cutting speed, 0.143 mm/rev feed rate and 1 mm depth of cut. However under
lower cutting conditions, a temperature of around 370 C near the cutting edge is observed. From Fig. 12(ac), the highest
cutting temperature results at the tip of the cutting edge, which clearly shows the basic machining characteristic of the low
thermal conductive Nickel based Nimonic C-263 material, which correlates the results reported by Smart et al. [26].
Apart from the low thermal conductivity, the specic cutting strength is high in the case of super alloys due to the pres-
ence of c0 precipitates and complex metallic carbides at the grain boundaries which inhibits the deformation and contribut-
ing to the generation of higher temperature at the shear zone. From the Fig. 12(ac), it can be seen that at all combination of
cutting conditions, highest temperature concentration results at the tip of cutting edge unlike steel machining, where the
higher temperature normally results at a nite distance from the cutting edge, thus identifying the basic material character-
istics of the Nimonic C-263 super alloy.

4.3. Effects of stress and strain at the tool work interface

During machining, the work material undergoes shear deformation when the cutting wedge indents on the work piece
and the magnitude varies depending upon the cutting conditions. Creep-resistant alloys like Nimonic C-263 are metallurgi-
cally designed to retain high strength at elevated temperatures and therefore, the stresses in the ow-zone are very high.
Figs. 13 and 14 illustrate the distribution of effective stress and strain, simulated using FEM in different machining condi-
tions, while turning the Nimonic C-263 alloy using a cemented carbide tool.
From Fig. 13(ac), it is observed that the magnitude of the effective stress tends to increase with the feed rate and cutting
speed increase. A maximum value of 720 MPa is observed at a cutting speed of 54 m/min. Larger deformation is more evident
in the tool work contact area where the chip curls more. As the cutting speed is increased from 22 m/min to 54 m/min, the
chip strain and strain rate is high, thus simulating larger strain to an extent of up to 5.4 mm/mm, as shown in Fig. 14(ac).
The predicted values of effective stress and strain using FEM simulation for different machining parameters on machining
the Nimonic C-263 alloy are shown in the Figs. 15 and 16. It is observed from the Fig. 15, that the effective stress increases
when the combination of cutting speed, feed rate and depth of cut increases. The nickel alloys have an austenitic matrix and
hence work harden rapidly, which produce a stressed layer deformed metal on the surface of the work. This causes harden-
ing effect and thus resulting into higher effective stress. In general, as the cutting speed is increased, there is an increase in
cutting temperature as observed in the Fig. 12, which normally reduces the strength of the material. But such phenomena is
Effective stresses (Mpa)

700

600

500

400

300

200
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experimental Number

Fig. 15. FEM simulation result of effective stress with respect to the L27 array.
Effective strain (mm )

7
6
5
4
3 Effective strain (mm/mm)

2
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Experiment Number

Fig. 16. FEM simulations result of effective strain with respect to the L27 array.
206 C. Ezilarasan et al. / Simulation Modelling Practice and Theory 40 (2014) 192207

not observed clearly in the Fig. 15, which could be due to the inherent thermal fatigue and creep characteristic that results by
the presence of higher cobalt percentage in the Nimonic C-263 super alloy.

5. Conclusions

Based on the results of the 3D FEM simulation and experimentation while turning the Nimonic C-263 alloy, using a PVD
coated cemented carbide cutting tool, the following conclusions were drawn:

 The percentage error observed between the experimental and FEM predicted values of cutting force is within 6% except in
a few experiments, which clearly indicates the close agreement between the FEM model and the experiment; thus, the
simulated FEM will be used effectively for predicting the cutting forces while turning the Nimonic C-263 super alloy.
 Depending on the cutting conditions, the cutting force varies between 390 N and 672 N. A steep increase in the cutting
force from 478 N to 672 N corresponding to the feed rates of 0.102 mm/rev to 0.143 mm/rev, identies the feed rate of
0.102 mm/rev as the critical feed rate for turning the Nimonic C-263 alloy.
 High temperature concentration was observed at the cutting insert tip in all the cutting conditions, unlike steel machin-
ing, where the higher temperature normally results at a nite distance from the cutting edge, which indicates the basic
material characteristics of the Nimonic C-263 super alloy.
 The highest cutting temperature occurred at the end of the cutting insert tip to an extent of 620 C at a combination of
54 m/min cutting speed, 0.143 mm/rev feed rate and 0.75 mm depth of cut.
 A maximum value of 720 MPa was observed at a cutting speed of 54 m/min. Larger deformation was more evident at the
tool work contact area where the chip curls more. As the cutting speed is increased from 22 m/min to 54 m/min, a larger
strain to an extent of up to 5.4 mm/mm was observed due to higher material deformation.

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