Numerical analysis of thermomechanical phenomena influencing tool wear in finishing turning of Inconel 718

• The paper focuses on the analysis of thermo–mechanical variables involved in tool wear mechanisms in turning Inconel 718.
• Despite the computational cost of 3D modeling, this approach is required for the analysis of phenomena involved in wear progression.
• Difficult to measure variables such as temperature and plastic strain directly related with tool wear were predicted.
• The trends observed for these predicted variables explain the wear patterns experimentally observed.

Inconel 718, one of the most used Ni alloys, is a low machinability material due to the elevated stresses and temperatures generated at the cutting edge during machining related to aggressive tool wear. The understanding of thermo-mechanical phenomena involved during cutting is required for enhancement of wear performance. In this work a three dimensional (3D) numerical model based on finite element (FE) is applied for simulation of dry turning of Inconel 718. Despite the elevated computational cost, 3D modeling is required for analysis of wear mechanisms. The model was validated with turning tests. Main wear modes experimentally identified (chipping, notching, built up edge BUE) were related to variables predicted using the numerical model, such as temperature and plastic strain at the chip. Good correlation between experiments and numerical results was observed, and strong influence of the side cutting edge in wear performance was found.