Inconel 718 is gaining its importance in the aerospace and power plant industries because of its high strength to weight ratio. The lack of understanding of the tool chip interface for Inconel 718 restricts the prediction of the apparent coefficient of friction and thus the cutting forces, thereby the machining efficiency. In the present study an analytical model has been developed accounting the actual variation of stresses over the rake face. The model focuses on the variation of shear stresses in the sticking region and has been considered to be increasing exponentially with distance from tool tip. The primary shear zone is assumed to be a thin layer with constant thickness and has been modelled using Johnson Cook material model. The shear stresses at the entry and exit of the primary shear zone has been calculated using iterative techniques proposed in the literature. The secondary shear zone has been analyzed dividing the contact length into two distinct regions and each region has been dealt separately. The ratio of real area of contact to the apparent area of contact has been given consideration and dealt with at macroscopic level. Experimental values have been extracted from previous studies on Inconel 718. The predictions of the analytical model was found to be in good agreement with experimental results. The experimental apparent coefficient of friction was obtained as 0.5119 against 0.4733 from the developed model at a velocity of 70 mm/min, depth of cut of 1mm, nose radius of 0.8mm and with negative rake angle (−6°) with CNMG0812 tool. The predicted and the experimental friction coefficient showed a variation of 7.07% – 10% and thus can serve as reliable model for Inconel 718.

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