A study on the machining characteristics of AISI 1045 steel and inconel 718 with circular cone shape in induction assisted machining

As the aerospace, aviation, and automobile industries have grown, the demand for difficult-to-cut materials such as Inconel and titanium has increased sharply, requiring the use of thermally assisted machining (TAM) to machine the difficult-to-cut materials. TAM is a highly efficient and environmentally friendly method in which materials are preheated and softened using various heat sources before machining. In TAM, difficult-to-cut materials have typically been preheated by laser device. However, such laser devices are expensive. Induction assisted machining (IAM) is proposed as an alternative with about one tenth the price of the laser device. Few studies of the IAM process have been conducted to date. In the present study, IAM was performed on AISI 1045 steel and Inconel 718 with circular cone shape. Experiments were conducted on the ramping and contouring milling method, respectively. Finite element analysis was performed to determine the effective depth of cut (EDOC). Results of analysis, EDOC was found 0.5 and 0.3 mm in the selected optimum preheating temperature of two materials, respectively. In addition, the efficiency of the IAM process was verified by comparing machining characteristics such as cutting force, specific cutting energy, surface roughness and tool wear based on feed rate in ramping and contouring machining method, compare with conventional machining (CM).