A simulation approach for estimating flank wear and material removal rate in turning of Inconel 718

• A simulation approach is proposed to estimate performance characteristics in turning.
• Analysis of variance identifies most influential parameters on flank wear and MRR.
• The model helps to accurately estimate the responses avoiding costly experiments.

The present work attempts to study the effect of important machining variables on performance characteristics such as material removal rate and tool wear in turning of Inconel 718 using chemical vapour deposition (CVD) coated tungsten carbide (WC) tool. A three dimensional machining model using Lagrangian approach has been developed using DEFORM 3D. The machining simulation is carried out to predict the flank wear and material removal rate (MRR). Flank wear is calculated using Usui’s wear model in the simulation model. The results from simulation model are compared with experimental data generated by the use of Taguchi’s L16 orthogonal array for reducing the experimental runs. Analysis of variance (ANOVA) is performed to identify the most influencing variables for both the performance characteristics. It is found that simulation results are in good agreement with experimental results. A valid simulation models helps the tool engineers to gather relevant process related information without resorting to costly and time consuming experimentation.