https://sam.ensam.eu:443 The DSpace digital repository system captures, stores, indexes, preserves, and distributes digital research material. Mon, 08 Jun 2026 14:47:38 GMT 2026-06-08T14:47:38Z http://hdl.handle.net/10985/15638 Prediction of form error during face turning on flexible Inconel 718 workpiece TOUBHANS, Bastien; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib Complex workpieces may contain thin sections that are more likely to deform during machining due to cutting forces. It may result in form errors on the final product. Then, it is important to anticipate such defects when programing tool paths. A mechanist formulation of the cutting forces model, considering tool wear, is proposed in association with a part flexibility model to determine elastic deformation during face turning of thin Inconel 718 discs. A specific experimental methodology has been developed to validate the simulation results by performing in-situ measurements of form error. Tue, 01 Jan 2019 00:00:00 GMT http://hdl.handle.net/10985/15638 2019-01-01T00:00:00Z TOUBHANS, Bastien VIPREY, Fabien FROMENTIN, Guillaume KARAOUNI, Habib Complex workpieces may contain thin sections that are more likely to deform during machining due to cutting forces. It may result in form errors on the final product. Then, it is important to anticipate such defects when programing tool paths. A mechanist formulation of the cutting forces model, considering tool wear, is proposed in association with a part flexibility model to determine elastic deformation during face turning of thin Inconel 718 discs. A specific experimental methodology has been developed to validate the simulation results by performing in-situ measurements of form error. http://hdl.handle.net/10985/18996 Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity TOUBHANS, Bastien; FROMENTIN, Guillaume; VIPREY, Fabien; KARAOUNI, Habib; DORLIN, Théo Machining accuracy can be compromised by elastic workpiece deformation and subsurface residual stress introduction during cutting. In order to anticipate the impact of cutting forces and surface integrity evolutions on finished surface and its geometrical errors, it is necessary to better understand the influence of cutting conditions and tool wear. In this study, machinability of Inconel 718 using a round carbide tool in finish turning conditions is assessed. Cutting forces evolution during tool life are analysed and accompanied by advanced investigations of cutting phenomena. An original mechanistic cutting force model is developed, identified and tested. It includes the effect of tool wear over time in its local formulation. This model allows predicting cutting forces evolution along tool pass for a wide range of finishing cutting conditions. Furthermore, a thorough analysis of residual stress profiles at different tool wear levels is led. It features quantitative results for fresh and worn tools. A study on the influence of cutting parameters and tool wear on residual stress profiles in the machining affected zone is highlighted. Wed, 01 Jan 2020 00:00:00 GMT http://hdl.handle.net/10985/18996 2020-01-01T00:00:00Z TOUBHANS, Bastien FROMENTIN, Guillaume VIPREY, Fabien KARAOUNI, Habib DORLIN, Théo Machining accuracy can be compromised by elastic workpiece deformation and subsurface residual stress introduction during cutting. In order to anticipate the impact of cutting forces and surface integrity evolutions on finished surface and its geometrical errors, it is necessary to better understand the influence of cutting conditions and tool wear. In this study, machinability of Inconel 718 using a round carbide tool in finish turning conditions is assessed. Cutting forces evolution during tool life are analysed and accompanied by advanced investigations of cutting phenomena. An original mechanistic cutting force model is developed, identified and tested. It includes the effect of tool wear over time in its local formulation. This model allows predicting cutting forces evolution along tool pass for a wide range of finishing cutting conditions. Furthermore, a thorough analysis of residual stress profiles at different tool wear levels is led. It features quantitative results for fresh and worn tools. A study on the influence of cutting parameters and tool wear on residual stress profiles in the machining affected zone is highlighted. http://hdl.handle.net/10985/20676 A versatile approach, considering tool wear, to simulate undercut error when turning thin-walled workpieces TOUBHANS, Bastien; LORONG, Philippe; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib In-process workpiece elastic deflection is the major source of geometrical error when machining low-stiffness workpieces. It creates an undercut error which needs to be corrected by time-consuming and labour-intensive operations. For this reason, cutting process simulation is growing in interest. To do so, a model representing the workpiece flexibility is coupled with a model to predict the applied cutting forces. For a given tool-material set, these cutting forces depend on the cut section, which therefore depends on current deflection of the part during machining, but also on the level of tool wear. This research work focuses on developing a general coupling approach to tackle this challenge. The case study is the finish turning on thin Inconel 718 discs. The cutting forces are predicted by a mechanistic model taking tool wear into account. The wear effect is expressed using the cumulative removed volume. The workpiece stiffness is determined with a reduced model using a modal basis. When dealing with large workpieces, it results in a remarkable computing time reduction during the time domain simulation. Cutting tests with varying engagements are simulated in a dexel-based versatile framework and undercut errors are compared to experimental observations. Fri, 01 Jan 2021 00:00:00 GMT http://hdl.handle.net/10985/20676 2021-01-01T00:00:00Z TOUBHANS, Bastien LORONG, Philippe VIPREY, Fabien FROMENTIN, Guillaume KARAOUNI, Habib In-process workpiece elastic deflection is the major source of geometrical error when machining low-stiffness workpieces. It creates an undercut error which needs to be corrected by time-consuming and labour-intensive operations. For this reason, cutting process simulation is growing in interest. To do so, a model representing the workpiece flexibility is coupled with a model to predict the applied cutting forces. For a given tool-material set, these cutting forces depend on the cut section, which therefore depends on current deflection of the part during machining, but also on the level of tool wear. This research work focuses on developing a general coupling approach to tackle this challenge. The case study is the finish turning on thin Inconel 718 discs. The cutting forces are predicted by a mechanistic model taking tool wear into account. The wear effect is expressed using the cumulative removed volume. The workpiece stiffness is determined with a reduced model using a modal basis. When dealing with large workpieces, it results in a remarkable computing time reduction during the time domain simulation. Cutting tests with varying engagements are simulated in a dexel-based versatile framework and undercut errors are compared to experimental observations. http://hdl.handle.net/10985/19639 Study of phenomena responsible for part distortions when turning thin Inconel 718 workpieces TOUBHANS, Bastien; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib; DORLIN, Théo Machining thin workpieces is a challenging task as geometrical errors may result from the combination of several phenomena. Among these, elastic workpiece deformation and machining induced residual stresses may be predominant sources due to low part stiffness. There is a lack of studies trying to quantify the influence of machining induced residual stresses on the total geometrical errors. A thorough experimental methodology is developed to quantify the influence of both phenomena separately by comparing the workpiece shape and dimensions, in-situ, before and after machining, using laser sensors. The proposed methodology can also be used to quantify the geometrical errors linked to clamping or stress rebalancing following material removal. The case study is the finish turning of thin Inconel 718 workpieces using carbide tools. In the studied case, machining induced residual stresses are responsible for 3–32 % of the total geometrical errors depending on tool wear and cutting parameters. Wed, 01 Jan 2020 00:00:00 GMT http://hdl.handle.net/10985/19639 2020-01-01T00:00:00Z TOUBHANS, Bastien VIPREY, Fabien FROMENTIN, Guillaume KARAOUNI, Habib DORLIN, Théo Machining thin workpieces is a challenging task as geometrical errors may result from the combination of several phenomena. Among these, elastic workpiece deformation and machining induced residual stresses may be predominant sources due to low part stiffness. There is a lack of studies trying to quantify the influence of machining induced residual stresses on the total geometrical errors. A thorough experimental methodology is developed to quantify the influence of both phenomena separately by comparing the workpiece shape and dimensions, in-situ, before and after machining, using laser sensors. The proposed methodology can also be used to quantify the geometrical errors linked to clamping or stress rebalancing following material removal. The case study is the finish turning of thin Inconel 718 workpieces using carbide tools. In the studied case, machining induced residual stresses are responsible for 3–32 % of the total geometrical errors depending on tool wear and cutting parameters.