Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy

•Cutting force (Fy), temperature generation at tool tip (Θ), effective stress and strain were predicted using ‘DEFORM 3D’.•The predicted values of responses were well validated with experimental results.•Highest cutting temperature occurred at tool tip to an extent of 610 °C.•Maximum effective stress generated to an extent of 720 MPa.•Experiments have been conducted using L27 orthogonal array.

The current paper presents the simulated 3D Finite Element Model (FEM) and experimental validation while turning the Nimonic C-263 super alloy using a cemented carbide cutting tool. FEM machining simulations was carried out using a Lagrangian finite element based machining model to predict the tangential cutting force, temperature distribution at tool tip and the effective stress and strain. All simulations were performed according to the cutting conditions designed, using the orthogonal array. The work piece was considered as perfectly plastic and its shape was taken as a curved model. An experimental validation of the cutting process was conducted in order to verify the simulated results of tangential cutting force and temperature at tool tip and the comparison shows that the percentage error 6% was observed and the shear friction factor 0.6 indicates good agreement between the simulated results and the experiment results. As the cutting speed is increased from 22 m/min to 54 m/min at higher feed rate, a larger strain to an extent of up to 6.55 mm/mm, a maximum value of 810 MPa stress and higher temperature localization to an extent of 620 °C at tool tip were observed.