Abstract
Machining parameters can influence fatigue life by altering residual stresses, cold work and surface roughness. A study was performed to examine the effect of various broaching machining parameters on high temperature fatigue lives of a nickel-based disk alloy. The influence of tool wear and broaching speed were studied and their effect on residual stresses, cold work and surface roughness was quantified. These variables were shown to have a substantial effect on fatigue lives, the failure mode type and location. The relationships between these parameters and fatigue crack initiation mechanisms are detailed. Statistical analyses evaluating these relationships are presented.
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