Numerical simulation study on drilling nickel-based superalloys with composite-coated tools

Abstract Because of their superior high-temperature mechanical qualities and resistance to corrosion, nickel-based high-temperature alloys find extensive application in the energy and aerospace industries. However, efficient manufacture is severely limited by their hard-to-machine features. This study uses numerical simulations based on the finite element program DEFORM 10.2 to solve the machining difficulties of Inconel 718 employing composite-coated twist drills. A three-dimensional finite element simulation model of the composite-coated tool and workpiece was created by combining the Usui wear model, the Cockroft–Latham fracture criterion, and the Johnson–Cook constitutive model. We evaluated and examined the cutting capabilities of uncoated, single-coated, and composite-coated tools. Results indicate that composite-coated tools significantly reduce axial force and torque during drilling. Maximum tool temperatures decrease by 18%–38% compared to uncoated tools, while chip morphology improves chip evacuation and machining stability. Further analysis reveals that feed rate most significantly influences cutting force and torque, while spindle speed also plays a crucial role in optimizing mechanical response and temperature distribution.