Numerical-simulation hybrid analysis of orthogonal cutting of Inconel 718

Inconel 718 is widely employed in the aerospace and energy sectors due to its exceptional mechanical and thermal stability, yet it remains one of the most challenging materials to machine. This study develops and validates a comprehensive three-dimensional finite element model using ANSYS to simulate orthogonal cutting of Inconel 718. The developed model incorporates Johnson-Cook constitutive and damage laws to represent strain hardening, rate sensitivity, thermal softening, and failure behaviour under high-speed cutting conditions. A full factorial design combined with response surface methodology was employed to analyze how variations in cutting speed, rake angle, nose radius, clearance angle, and depth of cut affect key machining responses, including cutting force, von Mises stress, cutting temperature, and energy consumption. Simulation outputs were rigorously validated against available experimental data, achieving close agreement. Parametric and ANOVA analyses revealed that rake angle and cutting speed significantly affect chip segmentation and thermal gradients. Empirical regression models demonstrated high predictive accuracy and were used for multi-objective optimization, yielding an optimal parameter set that minimized cutting force, energy, and thermal load. The findings provide a validated, computationally efficient simulation framework with direct relevance to machining process optimization and tool performance prediction in superalloy applications.