Inconel 718 presents significant challenges in machining attributable to the secondary hard niobium and titanium carbide phases. Machined surfaces typically show a tendency of those brittle carbides to crack, drag and smear under the cutting tool. This paper presents a finite element modeling approach to predict the carbide cracking and distortion phenomenon. The influence of cutting process parameters and cutting edge geometry on carbide damages will be investigated with the model. The model results will be qualitatively compared with SEM observations of the machined surfaces.

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