Journal of Cleaner Production 137 (2016) 1619e1627

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Journal of Cleaner Production

journal homepage: www.elsevier.com/locate/jclepro

A finite element based data analytics approach for modeling turning

process of Inconel 718 alloys
V. Vijayaraghavan a, *, A. Garg b, Liang Gao c, R. Vijayaraghavan d, Guoxing Lu e
a
School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore
b
Department of Mechatronics Engineering, Shantou University, Shantou 515063, China
c
The State Key Laboratory of Digital Manufacturing Equipment and Technology, 1037 Luoyu Road, Huazhong University of Science and Technology, Wuhan
430074, China
d
Aker Solutions Singapore Pte. Ltd., 73 Science Park Dr, Singapore, 118254, Singapore
e
Faculty of Science, Engineering and Technology, Swinburne University of Technology, Hawthorn, VIC, 3122, Australia

a r t i c l e i n f o a b s t r a c t

Article history: Turning is a primary metal cutting process deployed extensively for producing components to required
Received 29 September 2015 shape and dimensions. A commonly used material is Inconel 718, which exhibits an inferior economic
Received in revised form feasibility in terms of turning due to its poor machinability characteristics. A combined finite element
1 April 2016
based data analytics model is introduced in this work. Finite element modeling was used to predict the
Accepted 1 April 2016
Available online 9 April 2016
cutting force while Genetic Programming was used to obtain the mathematical relation between the
process variables and the cutting force. The weighted parameter analysis was conducted on the math-
ematical model which revealed that depth of cut and cutting angle exerts significant influence on the
Keywords:
Finite element analysis
cutting force. As turning process is generally specified by a given depth of cut which dictates the material
Machining removal rate, optimization of tool cutting angle can result in enhanced power savings. It is anticipated
Turning that the findings obtained from this study can result in greater power savings in turning process of hard-
Inconel 718 to-machine materials which can lead to a sustainable manufacturing process.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction
The recent spurt in emerging technologies in manufacturing
engineering sector has given rise to a greater demand for energy.
Manufacturing engineering components generally involves metal
cutting process such as turning, milling, grinding etc. The most
commonly used engineering material is the Inconel 718 which is a
Nickel based alloy and can be used for applications in space vehi-
cles, aircraft gas turbines, nuclear reactors, reciprocating engines,
petroleum industries and thermal exchangers (Olovsjo € et al., 2012;
Zhou et al., 2012; Cantero et al., 2013). The low machinability
characteristic of Inconel 718 makes the turning process a chal-
lenging task due to excessive tool wear resulting in excessive heat
generation and poor surface finish (Bhatt et al., 2010; Khidhir and
Mohamed, 2010). The power required for machining of Inconel
718 is normally fed through a central power distribution system
(Zhu et al., 2013). The cutting force is an expensive and essential
component for driving the metal cutting process. Optimizing cut-
ting force can directly regulate the power consumption in metal
* Corresponding author. Tel.: þ65 81847718.
E-mail address: ve0005an@e.ntu.edu.sg (V. Vijayaraghavan).
cutting industry which can result in greener and eco-friendly in-
dustrial process. Much of the earlier studies on turning process
have laid emphasis on machine process parameters on the me-
chanical properties such as wear, surface roughness, temperature
distribution of the material and machining tool (Zhao et al., 2002;
Fahad et al., 2012; Ezilarasan et al., 2014). With the focus for
green manufacturing taking center stage in recent days, some
studies have also been conducted to improve environmental per-
formance of certain manufacturing processes (Campatelli et al.,
2014; Emami et al., 2014). In this work, the authors have pre-
sented an attempt to formulate an integrated numerical model that
improves the sustainability of metal cutting of Inconel 718 alloy.
The machinability characteristics of Inconel 718 alloy has been
extensively researched in literature using laboratory based
machining experimentation and computational approaches. Thakur
et al. (2009) investigated the machinability parameters such as the
cutting temperature, surface roughness, cutting force, etc. while
subjecting Inconel 718 alloy to high speed machining. The studies
showed that the chip characteristics, surface integrity, shear angle
influences the machining properties of the Inconel alloy. Pawade
and Joshi (2011) applied Taguchi method for optimizing the

http://dx.doi.org/10.1016/j.jclepro.2016.04.010
0959-6526/© 2016 Elsevier Ltd. All rights reserved.
1620 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627
machining of Inconel alloy at high cutting velocities. They concluded
that the turning characteristics is vastly influenced by the tool cut-
ting depth. Zhu et al. (2013) conducted a review on machining
properties of Inconel 718. Their review indicated that a wide
research scope exists in understanding tool wear mechanisms by
considering the factors such as tool coating layer, monitoring the
machining process and tool geometry. Apart from experiments,
finite element modeling (FEM) has also been used in numerical
modeling and analysis of the mechanics of Inconel machining pro-
cess. Zhao et al. (2002) modeled the flank wear of orthogonal cutting
of Inconel 718 alloy by considering the material softening due to heat
buildup and the normal stress. Ze˛ bala and Słodki (2013) conducted
an FEM based analysis for investigating the effectiveness of chip-
breakers for machining of Inconel 718. The simulation showed that
the distance between the tool rake face and its cutting edge affects
the stress and temperature distribution in the tool. Lorentzon and
€rvstråt (2008) implemented an empirical cutting model in a
Ja
commercial FEM software to predict the machining characteristics
in turning of Inconel 718. In their work, they analyzed different
friction and wear models and assessed their impact on the wear
profiles generated from the finite element (FE) model.
Numerical studies based on FE models are widely used to un-
derstand and analyze the machining process of Inconel 718 alloy
when compared to that of performing expensive machining in lab-
oratory conditions. This is due to the reason that FE models serves as
a viable alternative to understand the wear mechanisms and chip
formation without conducting time consuming experiments for
monitoring machining process (Li, 2012; Senthilkumaar et al., 2012).
In addition, the FE models are capable of generating accurate solu-
tions and can give rapid insight to various parameters such as
pressure and temperature distribution of materials at low cost
 and Monno, 2010). These FE models can generate the
(Pittala
necessary data which can then be fed into an Artificial Intelligence or
other data analytics (DA) models (Yildiz, 2012, 2013a, 2013b, 2013c)
for formulating mathematical relationship between the various input
and output functions. Hence, the objective of the authors' research
work is to develop an integrated finite element based data analytics
(FE-DA) model that can integrate the advantages of these two nu-
merical approaches. The proposed model also helps the industry to
gain insight on the effect of input machining variables on the envi-
ronmentally effective manufacturing process of Inconel 718 alloy.
In this work, FE modeling has been performed to determine the
cutting force and power consumption required while turning the
Inconel 718 alloy based on the given process inputs viz. cutting
velocity, cutting angle, depth of cut and concentration of cutting
fluid. The data generated from the FE model is used to obtain an
explicit mathematical model of cutting force using DA approach.
The model performance is measured by comparing the results from
the DA model with that of the FEM calculated results and the most
dominant input factor that affects the cutting force of Inconel 718
alloy are determined.
2. An integrated FEM based DA approach
The machining characteristics of Inconel 718 have been modeled
in this work using an integrated FE modeling based DA modeling.
The input data obtained from FE modeling is combined with the
paradigm of a popular DA technique, genetic programming (GP). A
brief description of the FE modeling and the data analytics
modeling using GP technique is described in this section.
2.1. Description of FE modeling
For the purpose of conducting FE analysis, the commercial ABA-
QUS/Explicit Version 6.14 software with fully coupled thermal stress
analysis is deployed for modeling the contact mechanics between
the tool and workpiece. This is because metal cutting operation in-
volves combination of thermal and mechanical process. The thermal-
stress analysis model enables modeling the system geometry with
degrees of freedom corresponding to thermal and displacement ef-
fect. The explicit dynamics procedure is deployed which efficiently
describes the computation of large deformation and complex contact
mechanisms involved in cutting operation. Mesh distortion control is
obtained by the Arbitrary Lagrangian Eulerian (ALE) adaptive
meshing technique (ABAQUS 6.7 Analysis User's Manual, 2011). The
material constants of the workpiece and cutting tool used in the
simulation process (Mabrouki and Rigal, 2006; Uhlmann et al., 2007)
is illustrated in Table 1.
2.2. Material model used in FE modeling of turning process
Several mathematical models have been developed for FEM of
metal cutting process. In the present work, JohnsoneCook model has
been adopted since it best describes the strain rate, non-linear ma-
terial properties, high strain and strain hardening process involved in

turning operation (Uhlmann et al., 2007; Díaz-Alvarez et al., 2014).
The material fracture in the FE model is modeled using John-
soneCook model and the material constants used in the simulation
were directly extracted from Uhlmann et al. (2007). The flank wear
has exhibited by the cutting tool during process exerts notable effect
on the sustainability of turning operation. In the present simulation,
Usui model (Usui et al., 1984) is adopted for estimation of flank wear.
During each simulation run, the parameters such as interface tem-
perature, interface pressure and sliding velocity are noted. The flank
wear as given in Eq. (1) is then calculated as,
 
dw B
¼ Ast V exp (1)
dt q
2.3. Description of GP method
The FE model generates the required output based on the spe-
cific input process variables. Data analysis is then performed on
these results using GP algorithm. The principal objective of GP al-
gorithm is to find the optimal solution by imitating the natural
evolution process (Koza, 1992). The GP algorithm works by
considering the initial dataset of population from which a mathe-
matical relation is obtained by using functional elements and ter-
minal sets. Normally the functional elements are the standard
numerical operators (arithmetic, trigonometric or non-linear) and
the terminal set elements will be the input process variables. The
accuracy of the mathematical model so generated by the GP model
is tested using a fitness function, which will typically be given by
the mean square error (Vijayaraghavan et al., 2015). The evaluation
of the model accuracy is carried out by the GP algorithm until a
termination criteria is reached, which is user specified based on the
maximum permissible error or the number of generations. The new
Table 1
Material constants used in FE simulation (Mabrouki and Rigal, 2006; Uhlmann et al.,
2007).
Parameter Workpiece Tool
(Inconel 718) (tungsten carbide)
Thermal Conductivity, (k) 11.4 W/m/ C 50 W/m/ C
Density (r) 8700 kg/m3 11,900 kg/m3
Poisson's ratio (y) 0.29 0.22
Young's modulus (E) 205 GPa 534 GPa
Specific heat (Cp) 435 J/kg/ C 400 J/kg/ C
 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627 1621

Start

Define input and output process

parameters

FE model to generate data

Data fed into GP cluster

Check termination criteria

Perform genetic operations

on selected model Best model selected with
minimum training error

Create new population

Performance of best model

evaluated on training data
Performance evaluation of
models

Stop

Fig. 1. Flowchart describing the steps involved in integrated FEM-GP approach.

Fig. 2. Description of boundary conditions used in FE model of Inconel 718.

populations are then randomly selected and model is generated

until the termination criteria is reached. The individuals for the
genetic operations is selected by a tournament selection method
with preferred tournament sizes of 2,4 and 7. This method is
Fig. 3. Performance monitoring of flank wear in tungsten carbide tool during turning
considered suitable since it avoids the premature/local conver- of Inconel 718 alloy. The data obtained from the FEM simulation is compared with
gence by maintaining a genetic diversity in the population. The low experimental data from Yadav et al. (2015).
1622 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627

Fig. 4. Snap shots of various stages of turning operation of Inconel 718 alloy obtained from the FEM simulation. The tungsten carbide tool is initially kept at a horizontal clearance
distance from the workpiece (a), and is horizontally displaced along the surface of the Inconel 718 workpiece with constant depth of cut, cutting velocity, feed rate to effect turning
(b). The cutting action of the tool causes chip formation from the Inconel 718 workpiece (c).

fitness value models will be reproduced or replicated in the sub- which involves replacement of a branch of model with a new
sequent generations. In the present work, subtree crossover is random tree/model. The probability rate for the crossover, muta-
implemented which involves swapping of randomly selected tion and reproduction is kept at 80%, 6% and 14% respectively,
branches. Similarly, subtree mutation is deployed in this work which means that there will be a dominant crossover population.
 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627 1623

Table 2
Statistical metrics of datasets generated from the FE modeling.

Parameter Depth of cut, x1 Cutting velocity, x2 Feed rate, x3 Cutting angle, x4 Cutting fluid concentration, x5 Cutting force, y1 Power consumption, y2
(mm) (m/s) (mm/s) (degrees) (% vol) (N) (Watts)

Mean 0.6 0.2 0.26 45 6 40.5 8.1

Standard error 1.85 0.11 0.023 6.45 0.21 0.162 0.016
Median 0.6 0.2 4 45 4 57.45 11.49
Standard 0.026 0.99 1.99 9.15 2 2.269 2.160
deviation
Kurtosis 1.508 0.99 3.98 0.818 0.61 1.260 1.156
Skewness 0.660 1.22 5.22 0.595 0.102 0.073 0.089
Minimum 0.2 0.1 0.08 30 0 25.89 2.514
Maximum 1.0 0.3 0.20 60 6 75.47 21.567

The new population will be generated by means of iterative process

until the termination criteria is satisfied. The model with a mini-
mum error is selected as the best model and its performance
evaluation on the testing data is carried out. For better under-
standing, the steps involved in the integrated FE-DA approach is
given in the form of flowchart in Fig. 1.

3. Modeling the turning operation using FE modeling

The FE method which is used to simulate the turning operation

Fig. 5. Performance of the FEM based DA models of turning of Inconel 718 alloy
workpiece for cutting force where (a) represents training data and (b) represents the
testing data.
of Inconel 718 alloy and the subsequent validation by comparing
with experimental data is described in this section. At first, a 3D
solid model is created in commercially available FEM software,
ABAQUS. The 3D solid model consists of workpiece geometry which
is a prismatic rectangle and cutting tool which is triangular shaped
with an inclination angle c ¼ 90 , flank angle a ¼ 5 and rake angle
g ¼ 6 . In the simulation, workpiece is modeled as a deformable
plastic material whereas the cutting tool is treated as rigid material.
The workpiece and the tool geometry is discretized into eight-node
(CPE8RT) type elements with relative mesh size of 38,000 ele-
ments. The next step after the tool geometry definition is to fix the
boundary conditions of the workpiece and tool. The workpiece in
our simulation is set to be ENCASTRE which resembles completely
fixed and clamped state with no rotational or translational degrees
of freedom. The cutting tool is then given a displacement degree of
freedom along the cutting direction such that continuous chips are
formed from the workpiece. For better understanding, the
description of boundary conditions and the simulation procedure
used in this work is given in Fig. 2.
At the beginning of simulation, the tool and the workpiece are
set at 25  C which corresponds to the room temperature. A
conductive heat transfer coefficient of 500 kW/m2K (Coelho et al.,
2007) is defined which allows the heat transfer from the chip
surface to the cutting tool. The heat radiated from the free gener-
ated surface of the chip to the system surroundings and the thermal
transfer between the boundaries of the turned surface are negli-
gible and is not considered in this study. As explained in Section 2.2,
the JohnsoneCook constitutive failure model is used to simulate

the cutting process (Uhlmann et al., 2007; Díaz-Alvarez et al., 2014).
For the workpiece model, the ELEMENT DELETION is set to YES in
ABAQUS software. This is done to enable the chip to be separated
from the workpiece during the turning operation (Mabrouki et al.,
2008). To include the heat generation rate due to friction on the
toolechip interface and heat generation rate due to plastic

Table 3
Error metrics of the FE-DA model.

FE-DA model Total Mean Lower CI 95% Upper CI 95% Std dev SE mean Median Maximum Minimum

GP 63 2.45 1.39 3.52 4.21 0.53 0.37 15.53 0.006

ANN 63 3.12 1.64 4.18 4.56 0.69 0.54 16.07 0.007
1624 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627

Table 4 deformation, the INELASTIC HEAT FRACTION and the GAP HEAT
p-values of the DA models for cutting force. GENERATION modules of the ABAQUS software is invoked to
95% Confidence Interval GP ANN introduce the fraction of frictional work and the fraction of the
Mean paired t test 0.14 0.10
inelastic heat respectively (Priyadarshini et al., 2012).
Variance F test 0.90 0.79 The variation of flank wear of the cutting tool measured from
the FEM simulation with the process time is depicted in Fig. 3. For
validating the simulation data, the results of flank wear from
Table 5 experimental data obtained from Yadav et al. (2015) is also included
Relative contribution (%) of each input variable to the cutting force for the in the figure. It can be noted from this figure that the FEM simu-
turning process of Inconel 718. lation is able to simulate the machining performance of Inconel 718
Input variable Machining force subjected to turning operation. However, the estimated flank wear
from experiments is higher than that of the flank wear observed in
Depth of cut 35.47
Cutting velocity 15.82 simulation. This is due to the reason that in simulation, a perfect
Feed rate 10.32 tungsten carbide 3D model is considered. However, in actual ex-
Cutting angle 29.61 periments, the material used will have intrinsic defects. Further-
Cutting fluid concentration 8.78 more, in laboratory conditions while turning operation, the debris

Fig. 6. Analysis of cutting force of Inconel 718 alloy with specific input parameters.
 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627 1625

Fig. 7. Analysis of power consumption of Inconel 718 alloy with specific input parameters.

collected during turning of workpiece will also result in further
wearing of the tool material. Hence, it can be deduced that the
ability of FEM simulation to model the turning process of Inconel
718 alloy, in addition to complexity of conducting experiment
based machining makes it a viable option for generating data sets
for soft computing clusters for optimizing the turning process of
Inconel 718 alloy.
The simulation screen shots of the turning process of Inconel
718 alloy is depicted in Fig. 4. An initial clearance was given be-
tween the tungsten carbide tool bit and the Inconel 718 alloy
workpiece. Then tool bit is then given a horizontal displacement
such that it starts to chip away the material from the workpiece.
The tool is made to slide over the entire length of the workpiece
such that the chip material is completely removed from the
workpiece. A total of 5000 simulation steps are used during gen-
eration of each data point to compute the cutting force during the
turning process.
4. FE-DA model for cutting force analysis of Inconel 718 alloy
The FE modeling generates the values of cutting force and power
consumption by systematically varying the input turning parame-
ters, viz. depth of cut (x1), cutting velocity (x2), feed rate (x3), tool
cutting angle (x4) and cutting fluid concentration (x5). The input
variables were varied in the FE modeling by means of full-factored
design of experiments. The FE modeling resulted in 63 datasets and
the statistical metrics of the dataset is shown in Table 2. The dataset
is then divided in the ratio of 4:1 which were to be used for training
1626 V. Vijayaraghavan et al. / Journal of Cleaner Production 137 (2016) 1619e1627
and testing clusters of the GP algorithm respectively. The selection
of data clusters were done by Kennard-and-Stone algorithm and
the mode of selection plays vital role in the learning capability of
the algorithm. After this step, the optimum parameter settings of
the GP algorithm is selected which will determine the nature of the
numerical model. The parameter settings used in this study is ob-
tained from Vijayaraghavan et al. (2015).
4.1. Performance evaluation of FE-DA model
The performance of the FE-DA model is tested by calculating the
output process variables as predicted by the FE-DA model and
comparing it with cutting force obtained from FE modeling. The
accuracy of the model is tested using standard statistical error
functions as given in Vijayaraghavan et al. (2015). For the purpose of
comparison, artificial neural network (ANN) model (Zhao et al.,
2014a, 2014b) was also considered in modeling the mathematical
relationship. Fig. 5 shows the plot of cutting force data obtained
from the GP and ANN models. It can be seen that the proposed DA
models were able to confirm well to the data from the FE model.
The model values generated from ANN have better accuracy in the
training phase whereas, in testing phase, the GP has better
conformance with the FE generated data. Table 3 shows the
calculated statistical errors and the smaller values indicate the
better conformance of the DA model. The variation between the FE
and DA models can be evaluated using hypothesis testing (Table 4).
The computed p-values of hypothesis testing were lower than 0.05
which indicates no evidence of significant variation between the
cutting force calculated by the FE model and the DA models.
5. Analysis of cutting force and power consumption with
specific input process parameters
The information regarding the individual contribution of each of
the specific input process parameters towards the cutting force is
performed next. As can be seen in the previous section, the DA
technique provides a mathematical relationship between the
measured output variable (cutting force) with each of the four
specific input process variables. Using this model, a weighted
analysis is performed to determine which of the input exerts
maximum influence on the cutting force. The formula to measure
the weighted contribution is given in Vijayaraghavan et al. (2015).
The results of the weighted analysis of the specific input process
variables are shown in Table 5. It can be seen from this table that the
depth of cut exerts maximum influence on cutting force followed
by the cutting angle. It should however be noted in turning process,
the material removal rate (MRR) dictates the depth of cut and a
desired MRR would probably dictate the need for a specific depth of
cut. Hence, it is prudent to note that controlling the cutting angle
will result in an optimized cutting force and power consumption
that can lead to an environmentally friendly turning process. The
plots of variation of cutting force with individual input process
variable is shown in the form of graphs in Fig. 6. These plots helps
us to validate certain phenomena observed in experiment (Yadav
et al., 2015), for instance, the near linear increase of cutting force
with depth of cut and its non-linear variation with the feed rate and
cutting velocity. In addition to cutting force, the variation of power
consumed in the turning process of Inconel 718 alloy with input
process parameters is depicted in Fig. 7. It can be seen from Fig. 7
that the variations in depth of cut and cutting velocity can lead to
major influence on the power consumption. Hence, it can be
concluded from these analyses that optimizing the cutting angle
can reduce the cutting force which in turn can minimize the power
consumption during turning process thereby making it more
environmentally effective.
6. Conclusions
The present work introduced a theoretical approach for
improving the sustainability of hard to machine alloys such as
Inconel 718. An initial FE modeling was done to predict the cutting
force and power consumption with input process variables and
subsequently data analysis was applied on the data generated by
the FE model. The data analysis performed using genetic pro-
gramming resulted in a mathematical model and the validation of
model was carried out by comparing the computed tool flank wear
with the available experimental data. This would mean that the
proposed analytical approach can be used in tooling and machining
shop floors for optimizing the power consumption without having
the need to perform trial experiments on hard to machine alloys or
components. Furthermore, the effect of individual input process
variable on the cutting force and power consumption was also
analyzed using a weighted analysis technique. It was found that the
depth of cut exerts significant influence followed by the cutting
angle. Since the MRR in turning process dictates a specific depth of
cut, it can be inferred that optimizing the cutting angle can result in
reduced cutting force and subsequently lower power consumption.
Hence, an increased energy savings can be obtained in
manufacturing lines involving hard-to-machine materials thereby
achieving a sustainable manufacturing approach.
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