Study of the Thermal History upon Residual Stresses during the Dry Drilling of Inconel 718

The main objective of this article was to show for the first time that heat transfer plays a major role in residual stress generation during the dry drilling of Inconel 718, and to propose a numerical strategy capable of simulating such thermo-mechanical phenomena. An X-ray diffraction (XRD) analysi...

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Bibliographic Details
Published in:Metals (Basel ) 2022-02, Vol.12 (2), p.305
Main Authors: Chenegrin, Kévin, Bouscaud, Denis, Girinon, Mathieu, Karaouni, Habib, Bergheau, Jean-Michel, Feulvarch, Eric
Format: Article
Language:English
Subjects:
Boundary conditions
Drilling
drilling simulation
dry drilling
Engineering Sciences
Geometry
Heat
Inconel 718
Lubricants & lubrication
Mechanical components
Nickel base alloys
Overheating
Residual stress
residual stresses
Service life assessment
Simulation
Superalloys
thermal analysis
Three dimensional models
Titanium alloys
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Summary:The main objective of this article was to show for the first time that heat transfer plays a major role in residual stress generation during the dry drilling of Inconel 718, and to propose a numerical strategy capable of simulating such thermo-mechanical phenomena. An X-ray diffraction (XRD) analysis shows that without lubrication, high tensile residual stresses can be observed on the surface of a deep through drilled hole. Such a situation can be highly detrimental for the fatigue lifetime of a mechanical component. A thermal history in five phases is first identified by means of temperature measurements exhibiting an overheating of approximately 500 ∘C on the created hole surface just before the end of the drilling operation. A 3D thermo-viscoplastic model is herein improved in terms of boundary conditions to show that this phenomenon is triggered by the progressive decrease in the Inconel 718 volume under the cutting zone. To the authors’ knowledge, such a phenomenon has never been reported and simulated before in the literature. Then, a 3D thermo-elasto-plastic simulation including elasticity is proposed to compute residual stresses from the thermal results of the previous model. It shows for the first time that the overheating stage induces sufficiently intense plasticity to produce high tensile residual stresses of approximately 900 MPa as we experimentally observed.
ISSN:2075-4701
2075-4701
DOI:10.3390/met12020305