Inconel 718 nickel-based super alloy is widely used in aerospace, nuclear and marine industries due to its important thermo-mechanical properties and excellent corrosion resistance. However, the possibility to produce parts with a superior surface quality (e.g. enhanced surface integrity) still represents a challenge for manufacturing industry since the standard processing parameters are not suitable when difficult-to-cut materials are involved. Thus, predictive models represent a useful tool to simulate the material behavior during machining. Physics based computational analysis is an excellent technique to analyze the micro-scale phenomena (e.g. dynamic recrystallization, density of dislocation changes) taking place during the plastic deformation processes. Thus, it represents an important tool to optimize the cutting process achieving the desired characteristics of the machined surface. This work presents a physics based model developed to assess the micro-mechanical behavior of Inconel 718 super alloy subject to severe machining operations. Results show the good capability of the model to properly deal with the main physical phenomena taking place during the process and to correctly predict the main surface modifications which affect the final product performance.
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