Experimental and numerical investigations of aerospace alloys: Effect of machining

Aerospace materials like Ti6Al4V and Inconel 718 have exceptional abilities such as high strength, good corrosion resistance, and low specific weight. These properties make them difficult to machine due to rapid tool wear, high cutting forces, and heat generation. Microstructural characterization has been performed for these alloys to identify the phases and precipitates. With the help of machining simulations, experimental trial and error can be avoided. Numerical simulations predict the behavior of materials like Ti6Al4V and Inconel 718 under various machining conditions. They provide insights into stress distribution, temperature rise, and chip formation, which are crucial for understanding how these materials respond to machining. By simulating different cutting parameters (e.g. speed, feed rate, and depth of cut), optimal conditions can be identified to minimize tool wear, improve surface finish, and reduce machining time. Achieving a high-quality surface finish is challenging with these materials. Simulations can predict the impact of different machining parameters on surface integrity, allowing for adjustments before actual machining. Three-dimensional finite element-based m