Experimental Study on the Performance of Hydraulic Vibration Assisted Broaching (HVAB) Based on Piezoelectric Sensors

Zhen Meng,Xiang-Qi Liu,Jing Ni,Yu Shi,Chuan-Yu Wu

doi:10.3390/s18082417

Zhen Meng, Xiang-Qi Liu + Show 3 more

Open Access

https://doi.org/10.3390/s18082417

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Abstract

In order to improve the keyway broaching process and verify the feasibility of vibration-assisted broaching process, an experimental study on a novel hydraulic vibration assisted broaching (HVAB) system with double-valve electro-hydraulic exciter (DVEHE) is proposed in this paper. The performances of HVAB at different excitation frequencies were compared from three aspects: (a) the cutting force under the different vibration frequencies, (b) the surface roughness of the workpiece, and (c) the flank face wear of the tool. For precision on-line measurement of larger broaching forces, four piezoelectric sensors were fixed on the broaching machine. The experimental results show that HVAB can effectively improve the performance of the broaching process, approximately reduce the broaching force by as much as 9.7% compared to conventional broaching (CB) and improve the surface quality of workpiece. Some explanations are offered to support the observations.

Highlights

Keyway broaching is a metal cutting process that gradually removes material by pulling a multi-toothed tool through a work piece, which has a wide field of application in automotive and aeronautic industries [1,2]
In the last two decades, in order to reduce the wear of broach and increase its lifespan, improve the surface precision of the workpiece [6], researchers have put much effort into optimizing the parameters of broaching tools, such as the modification of geometric model for the broaching tools [7,8], optimization parameters of rake angle, clearance angle and rise per tooth (RPT) [3,9,10]
Workpiece contact ratio, the portion of each cycle where the broach is in contact with the workpiece is larger. These results show that hydraulic vibration assisted broaching (HVAB) can reduce tool wear compared to conventional broaching (CB)

Summary

Introduction

Keyway broaching is a metal cutting process that gradually removes material by pulling a multi-toothed tool through a work piece, which has a wide field of application in automotive and aeronautic industries [1,2]. In order to reduce broach wear and prolong tool life, the improvement of broaching process is becoming a research hotpot [5]. In the last two decades, in order to reduce the wear of broach and increase its lifespan, improve the surface precision of the workpiece [6], researchers have put much effort into optimizing the parameters of broaching tools, such as the modification of geometric model for the broaching tools [7,8], optimization parameters of rake angle, clearance angle and rise per tooth (RPT) [3,9,10]. Klocke et al [11] used carbon free cutting material MC 90 to replace the speed steel for broach tool, which processed a higher hot hardness and increased thermal conductivity. Ni et al [5] proposed a surface textured broach to improve broaching performance

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Discussion

Conclusion