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The Estimation of Cutting Forces in the Turning of Inconel 718 Assisted … 149

The effect of HPC on the performance of machining of nickel-based alloys has been
investigated by many authors. Ezugwu Ezugwu and Bonney (2004) analyzed tool life,
surface roughness, tool wear and component forces using high-pressure coolant supplies
in rough turning of Inconel 718 with coated carbide tools. The test results show that
acceptable surface finish and improved tool life can be achieved using HPC technique.
Ezugwu (Ezugwu and Bonney (2005)) investigated same parameters in finish machining
of Inconel 718 with coated carbide tool under high-pressure coolant supplies. The results
indicate that acceptable surface finish and improved tool life can be achieved with high
coolant pressures. Cutting forces were increased with increasing cutting speed due
probably to reactive forces introduced by the high-pressure coolant jet. Nandy,
Gowrishankar, and Paul (2009) investigate effects of high-pressure coolant on machining
evaluation parameters such as chip form, chip breakability, cutting forces, coefficient of
friction, contact length, tool life and surface finish. The results show that significant
improvement in tool life and other evaluation parameters could be achieved utilizing
moderate range of coolant pressure. Empirical modeling of machining performance under
HPC conditions using Taguchi DOE analysis has been carried out by Courbon et al.
(2009). Regression modelling was used to investigate the relationships between process
parameters and machining responses. It has been demonstrated that HPC is an efficient
alternative lubrication solution providing better chip breakability, reductions in cutting
forces and advantages regarding lubrication and thermal loads applied to the tool.
Furthermore, this cooling/lubrication technique can improve surface finish allowing for
an optimal pressure/nozzle diameter/cutting speed combination. Colak (2012) study the
cutting tool wear and cutting force components, while machining Inconel 718 under the
high pressure and conventional cooling conditions. Experimental results were analyzed
by using ANOVA and regression analysis. The results have proven that the tool flank
wear and cutting forces considerably decrease with the delivery of high pressure coolant
to the cutting zone. Klocke, Sangermann, Krämer, and Lung (2011) analyzed the effect of
high-pressure cooling in a longitudinal turning process with cemented carbide tools on
the tool wear, cutting tool temperature, resulting chip forms as well as the ratio of cutting
forces and tool-chip contact area. The results suggest that the tool temperature can be
significantly decreased by the use of a high-pressure coolant supply and that due to the
different tool wear mechanisms and the change in the specific load on the cutting edge
during machining, the resulting tool wear was influenced differently.
One of the most important factors in machining processes is accurate estimation of
cutting forces due to their significant impacts on product quality. Modeling and
prediction of optimal machining conditions for minimum cutting forces plays a very
important role in machining stability, tool wear, surface finish, and residual stresses. In
this regard, cutting forces have been investigated by many researchers in various
machining processes through formulation of appropriate models for their estimation. The
most frequently used models for prediction of cutting forces are mathematical models