Abstract
Complex profile broaches are widely used in the manufacture of complex parts of aero-engines, but the forces in the broaching process are difficult to predict and control. A new numerical model for broaching force with complex profile tools was presented, which considered the area and arc length of the curved shear zone boundary. The area and arc length were calculated by the curve function of the boundary, which is firstly predicted by FEM simulation. Then, an experimental device was set up to carry out the broaching experiment with straight profile tools and complex profile tools in accordance with the progressive depth of the cut. Based on the experiments, the traditional broaching model and the modified model with the complex profile tool have been established. Compared with the traditional force model, the accuracy of the modified model has been moderately improved. Furthermore, the modified main broaching force (Y direction) model and the normal force (Z direction) model show a significant improvement in accuracy of 4.8% and 9.7%, respectively, which suggests that the projection area of curved shear zone A1 and the projection arc length of curved shear zone l1 have a big impact on the broaching process. It is firmly believed that the modified model proposed in this paper can provide guidance for the design of complex profile tools and facilitate the efficient and high-precision machining of complex parts.
Highlights
Inconel 718, as a kind of nickel-base superalloy, has been widely used in the manufacture of aero-engine and gas turbine components due to its high creep strength, comprehensive mechanical properties, and cavitation resistance [1,2,3,4]
As for cutting modelling of complex profile tools, a great amount of work have done by predecessors, and most of the models can be categorized as theoretical analytical model [10,11], mechanistic model [12,13], empirical model [14,15] and finite element model [16,17]
Based on the Coupled Eulerian-Lagrangian (CEL) finite element model, Peng et al [24] considered the effect of the tool flank wear on the cutting force modelling, and the flank wear of the actual tool was measured by laser scanning microscope, the geometric model was updated in the pretreatment of the simulation, so as to improve the cutting force modelling accuracy
Summary
Inconel 718, as a kind of nickel-base superalloy, has been widely used in the manufacture of aero-engine and gas turbine components due to its high creep strength, comprehensive mechanical properties, and cavitation resistance [1,2,3,4]. It is necessary to build a more accurate cutting force prediction model in the machining process of nickel-base alloy with complex profile tools. Fabre et al [22] established a circular internal broaching force model with a complex profile through an empirical formula, in which the radial cutting force was predicted precisely. It is believed that to further improve the accuracy of the cutting force prediction model, it is necessary to consider the complicated deformation of the shear zone caused by the complex profile tool. In this paper, a novel broaching force model based on the projection area of the curved shear zone was proposed, and the 3D finite element simulation was employed to predict the area and arc length of the curved shear zone projection. The area and arc length of the above two projection surfaces are used to characterize the cutting force
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