Estimation of induced residual stresses and corrosion behavior of machined Inconel 718 superalloy: 3D-FE simulation and optimization
| Autor: | Khalaf Nasralla, Adel K. Mahmoud, Suha K. Shihab, Jabbar Gattmah |
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| Rok vydání: | 2021 |
| Předmět: | |
| Zdroj: | International Journal of Computational Materials Science and Engineering. 11 |
| ISSN: | 2047-685X 2047-6841 |
| DOI: | 10.1142/s2047684121500287 |
| Popis: | Nickel super alloys like Inconel 718 characterize a significant metal part in the structures of aircraft and engine components. The high reliability levels are the major conditions during the manufacturing of these essential structural components in aerospace production. Surface integrity is the most important factor considered for estimating the quality of machined surfaces in term of finishing as well as strongly effect on the corrosion behavior of the machined surface. In this study, three-dimensional (3D)-finite element (3D-FE) simulations were accomplished to determine induced residual stresses in machined Inconel 718 alloy. 3D simulations were executed in the sequential successive method using the design of experiments (DOEs) based on Taguchi L9 technique. Subsequently, a veritable turning was implemented based on the selected Taguchi design to validate the simulation results. Also, the efficiency of independent parameters (cutting speed, feed rate, and depth of cut) on the surface integrity (surface roughness, microhardness, induced residual stresses), and corrosion rate of the machined surface were explored experimentally. Based on analysis of variance (ANOVA), it was obtained that the feed rate is the most relevant factor related to surface roughness and corrosion rate while cutting speed is the most relevant factor related to microhardness and induced residual stresses. The analyzed polarization curves confirmed that the reducing surface roughness and increasing induced compressive residual stresses are robustly related to enhancing the corrosion behavior of Inconel 718. Robust agreement was detected between the predicted and measured data. The optimal values of independent parameters that led to optimal surface integrity and minimum value of corrosion rate were found. Based on the revealed simulation results, the 3D-FE simulation of the turning process afforded consistent data as compared to experimental measurements for the wide range of induced residual stresses. |
| Databáze: | OpenAIRE |
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