Predictive Thermal Modeling and Finite Element Simulation for Enhanced Surface Integrity in High-Speed Milling of Nickel-Based Superalloys
Year: 2026
Type: book-chapter
Abstract: Maintaining surface integrity during high-speed milling (HSM) of nickel-based superalloys remains a central challenge for aerospace and energy sectors due to extreme thermal loads at the tool-workpiece interface.Excessive thermal gradients accelerate tool wear, induce microstructural degradation, and trigger tensile residual stresses on machined surfaces.This research presents a coupled thermo-mechanical modeling framework integrating predictive thermal analysis and finite element simulation to control heat generation during HSM of Inconel-718.A physics-driven analytical heat model is employed to estimate transient temperature distributions, while a 3D finite element model predicts chip formation, thermal softening, and surface integrity metrics including white layer formation, microhardness variation, and residual stress fields.Experimental validation performed with varying cutting speeds (60-120 m/min), feed rates, and coated carbide tools demonstrates strong correlation between predicted and measured surface responses.Results show that optimized parameters effectively suppress thermal stress concentrations, reduce adverse tensile stresses, and improve fatigue-resistant surface quality.The findings provide an advanced predictive toolset for machining parameter optimization and reliable highperformance manufacturing of superalloy components.
Authors: Nidhi Singh, Kriti Srivastava, Shweta Mishra
Institution: Dr. Ram Manohar Lohia Avadh University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
OpenAlex ID: W7204792190