Inconel 718 alloy is known as difficult to cut and generally requires the use of cutting fluids. These represent a source of pollution and a significant fraction of the workpiece cost. The wish is then to migrate to dry and high speed machining. However, due to mechanical and refractory properties of Inconel 718, the surfaces generated can then be damaged. The objective of this study is double: to show that dry machining of Inconel 718 is possible and to develop experimental and simulation tools to qualify the machining, especially for peripheral milling. First, lubrication and dry turning were performed under conditions of semi-finishing with coated tungsten carbide tools. Surfaces and under surfaces were observed and described by a variety of means: interferometric microscope, scanning electron microscope, microhardness, X-ray goniometer for the analysis of residual stresses. Analysis shows the feasibility of dry cutting and highlights the main influential factors induced surface integrity, particularly cutting temperature. Then, a cutting temperature control technique was developed for a milling operation, based on the technology of thermocouples. Tests were conducted on Inconel 718, showing the high temperature gradient from the surface to the subsurface (up to 400 °C in 0.5 mm at a cutting speed of 320 min)), but also measuring the temperature variation of the tool cutting edge during one rotation (up to 550 °C for a cutting speed of 320 m/min) Finally, an analytical modelling was developed for peripheral milling, based on a thermomechanical approach. It allows evaluating cutting forces. Experimental tests were performed for various cutting conditions and a quite satisfactory comparison between experimental results and modelling of the process is proposed. An extension of this approach to validate the thermal aspect is however considered.
