Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617

Chandramani Upadhyay; Sumit Singh Rajput; Vivek Kumar Sahu; Soumya Gangopadhyay; Susanta Kumar Sahoo

doi:10.1007/978-981-95-2535-5_15

Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617

Chandramani Upadhyay
, Sumit Singh Rajput
, Vivek Kumar Sahu
, Soumya Gangopadhyay^*
, Susanta Kumar Sahoo

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiC_w + Al₂O₃, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiC_w + Al₂O₃ tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiC_w + Al₂O₃ emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.

Original language	English
Title of host publication	Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023
Editors	J. Ramkumar, P. Bhardwaj, Khan Khan D., S. Dodla
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	189-198
Number of pages	10
ISBN (Print)	9789819525348
DOIs	https://doi.org/10.1007/978-981-95-2535-5_15
State	Published - 2026
Externally published	Yes
Event	9th International and 30th All India Manufacturing Technology, Design and Research Conference, AIMTDR 2023 - Varanasi, India Duration: 8 Dec 2023 → 10 Dec 2023

Publication series

Name	Lecture Notes in Mechanical Engineering
ISSN (Print)	2195-4356
ISSN (Electronic)	2195-4364

Conference

Conference	9th International and 30th All India Manufacturing Technology, Design and Research Conference, AIMTDR 2023
Country/Territory	India
City	Varanasi
Period	8/12/23 → 10/12/23

Bibliographical note

Publisher Copyright:
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2026.

Keywords

Dry machining
FE simulation
Inconel 617
SiAlON
SiC + AlO
WC

ASJC Scopus subject areas

Automotive Engineering
Aerospace Engineering
Mechanical Engineering
Fluid Flow and Transfer Processes

Access to Document

10.1007/978-981-95-2535-5_15

Cite this

Upadhyay, C., Rajput, S. S., Sahu, V. K., Gangopadhyay, S., & Sahoo, S. K. (2026). Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617. In J. Ramkumar, P. Bhardwaj, K. Khan D., & S. Dodla (Eds.), Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023 (pp. 189-198). (Lecture Notes in Mechanical Engineering). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-981-95-2535-5_15

Upadhyay, Chandramani ; Rajput, Sumit Singh ; Sahu, Vivek Kumar et al. / Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617. Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023. editor / J. Ramkumar ; P. Bhardwaj ; Khan Khan D. ; S. Dodla. Springer Science and Business Media Deutschland GmbH, 2026. pp. 189-198 (Lecture Notes in Mechanical Engineering).

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title = "Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617",

abstract = "This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiCw + Al2O3, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiCw + Al2O3 tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiCw + Al2O3 emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.",

keywords = "Dry machining, FE simulation, Inconel 617, SiAlON, SiC + AlO, WC",

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note = "Publisher Copyright: {\textcopyright} The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2026.; 9th International and 30th All India Manufacturing Technology, Design and Research Conference, AIMTDR 2023 ; Conference date: 08-12-2023 Through 10-12-2023",

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Upadhyay, C, Rajput, SS, Sahu, VK, Gangopadhyay, S & Sahoo, SK 2026, Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617. in J Ramkumar, P Bhardwaj, K Khan D. & S Dodla (eds), Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023. Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, pp. 189-198, 9th International and 30th All India Manufacturing Technology, Design and Research Conference, AIMTDR 2023, Varanasi, India, 8/12/23. https://doi.org/10.1007/978-981-95-2535-5_15

Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617. / Upadhyay, Chandramani; Rajput, Sumit Singh; Sahu, Vivek Kumar et al.
Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023. ed. / J. Ramkumar; P. Bhardwaj; Khan Khan D.; S. Dodla. Springer Science and Business Media Deutschland GmbH, 2026. p. 189-198 (Lecture Notes in Mechanical Engineering).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617

AU - Upadhyay, Chandramani

AU - Rajput, Sumit Singh

AU - Sahu, Vivek Kumar

AU - Gangopadhyay, Soumya

AU - Sahoo, Susanta Kumar

N1 - Publisher Copyright: © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2026.

PY - 2026

Y1 - 2026

N2 - This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiCw + Al2O3, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiCw + Al2O3 tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiCw + Al2O3 emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.

AB - This study presents a comprehensive investigation into chip characterization during the turning of Inconel 617, employing three different cutting tool materials: WC, SiAlON, and SiCw + Al2O3, while maintaining a constant feed rate and depth of cut at 0.15 mm/rev and 0.5 mm, respectively. The research encompasses three distinct cutting speeds, namely, 50, 150, and 250 m/min. Notably, finite element (FE) simulations exhibit good agreement with experimental results at a 50 m/min cutting speed, revealing significant insights. It is observed that WC tools outperform SiAlON inserts in terms of lower main cutting forces and cutting temperatures, effective stress, effective strain, and superior chip reduction coefficient at lower cutting speed, while SiCw + Al2O3 tools consistently yield lower chip reduction coefficients. Interestingly, at the other two cutting speeds (150 and 250 m/min), SiAlON tools exhibit superior chip reduction coefficients compared to WC tools. SiCw + Al2O3 emerges as the most effective tool insert for the present machining conditions. These findings contribute valuable knowledge for optimizing machining processes in high-temperature alloy applications, making it possible to enhance performance and efficiency across varying cutting speeds.

KW - Dry machining

KW - FE simulation

KW - Inconel 617

KW - SiAlON

KW - SiC + AlO

KW - WC

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AN - SCOPUS:105038358030

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Upadhyay C, Rajput SS, Sahu VK, Gangopadhyay S, Sahoo SK. Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617. In Ramkumar J, Bhardwaj P, Khan D. K, Dodla S, editors, Modeling and Simulation in Manufacturing - Proceedings of the AIMTDR 2023. Springer Science and Business Media Deutschland GmbH. 2026. p. 189-198. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-981-95-2535-5_15

Finite Element Simulation of Chip Formation and Experimental Characterization During Dry Machining of Inconel 617

Abstract

Publication series

Conference

Bibliographical note

Keywords

ASJC Scopus subject areas

Access to Document

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Cite this