Predictive Thermal Modeling and Finite Element Simulation for Enhanced Surface Integrity in High-Speed Milling of Nickel-Based Superalloys

DOI

10.2991/978-94-6239-750-7_10How to use a DOI?

Keywords

High-speed milling; Nickel-based superalloy; Predictive thermal modeling; Finite element simulation; Surface integrity; Inconel-718

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 high-performance manufacturing of superalloy components.

Copyright

© 2026 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Nidhi Singh
AU  - Kriti Srivastava
AU  - Shweta Mishra
PY  - 2026
DA  - 2026/08/31
TI  - Predictive Thermal Modeling and Finite Element Simulation for Enhanced Surface Integrity in High-Speed Milling of Nickel-Based Superalloys
BT  - Proceedings of the International Conference on Advanced Design, Manufacturing, and Sustainable Energy Systems (ICADMSES 2026)
PB  - Atlantis Press
SP  - 133
EP  - 144
SN  - 2589-4943
UR  - https://doi.org/10.2991/978-94-6239-750-7_10
DO  - 10.2991/978-94-6239-750-7_10
ID  - Singh2026
ER  -