Experimental and Numerical Investigations on Machining Induced Surface Integrity in Inconel-100 Nickel-Base Alloy

Nickel-base alloys such as Inconel-100(IN-100) are still the most preferred material for jet engine and gas turbine components.Machining induced surface integrity plays a vital role for component fatigue life and reliability.This studyinvestigates the effects of machining conditions (tool geometry, coating, and cutting parameters) on the resultant residual stress, microhardness and grain size inmachiningIN-100. Experimental results for measured forces, residual stress, microhardness, and grain size have been presented. In addition, finite element modeling based investigations have been performed to predict not only residual stresses but also microstructureincluding dynamic recrystallization by implementing the Johnson-Mehl-Avrami-Kolmogorov model. Numerical modeling results were compared with experimental measurements in residual stresses, grain size and microhardness. The effects of cutting conditions on machining induced residual stress, microhardness, and average grain size have been reported.