Broaching Machine Research Articles

METHOD OF STATISTICAL CONTROL OF A PRODUCTION PROCESS

This study presents a statistic control method for the manufacturing process. This control applies on the most diverse industrial areas such as production lines, data traffic, medical system, the evolution of social media or economic system and is one of the main tool used in the control and management of quality. We based this work on the use of the equipment of measuring horizontal projector type of profiles, StarrrettOptical, from the laboratory equipment. We can imagine an algorithm of measuring for the item “washer” and on the algorithm base, we create a measuring program of this item. Moreover, in this paper, we present on to detail the programming mode of the QuadraCheck 200 system which equip the horizontal projector for profile StarrettOptical. On the base of the data set got through a lot of measures of 14 items got through broaching on the broaching machine DPM 08 84, from the laboratory equipment, we analysed broaching process capabilities and we calculate data capability of this process and of this machine.

Tool Fracture Detection in Electromechanical Broaching Through Machine Sensor

Broaching is a machining technique that plays a crucial role in the quality and integrity of manufactured products as it demands superior surface quality and precision compared to other machining methods. Monitoring tool condition is essential, as a damaged tool can significantly affect the quality of the surface finish and integrity of the final part causing irreparable damage to both the part and the work tool.This paper presents the development of a virtual sensor designed for the real-time detection of tool fractures during the broaching process, allowing timely decision-making without generating greater damage to the part or tool. The virtual sensor is created using signals collected from the broaching machine's data, without the need for external sensors; having the potential to improve product quality, increase process efficiency, and reduce material waste as well as production costs by detecting tool fractures early and, therefore, increasing the overall sustainability of the process.

Structural and Modal Analysis of the Unloading Robot on the Broaching Machine

In order to meet the actual production of a machining company in the low production efficiency, labor intensity, process flow complexity and other real problems, the broaching machine processing upgraded and designed a broaching machine for the production of automatic loading and unloading device. This paper analyzes the layout scheme and workflow of automatic loading and unloading, designs the overall structure of the loading and unloading device and key components, and establishes a three-dimensional model through Solidworks software, and carries out a static analysis of the limit position in the operation process by using the finite element analysis software ANSYS Workbench, and obtains the maximum deformation under the limiting conditions of 0.1129mm, and the maximum stress value of 24.236MPa. The maximum deformation is 0.1129mm and the maximum stress is 24.236MPa. Subsequently, modal analysis is carried out to extract the first 6 orders of intrinsic frequency and corresponding vibration pattern, and harmonic response analysis is carried out on the weak components on the basis of modal analysis, which verifies that the structure complies with the design requirements in terms of strength, stiffness and resonance of the whole machine, and it provides the theoretical basis for the subsequent structural improvement and optimization design.

Early detection of tool wear in electromechanical broaching machines by monitoring main stroke servomotors

This paper aims to provide researchers and engineers with evidence that sensorless machine variable monitoring can achieve tool wear monitoring in broaching in real production environments, reducing production errors, enhancing product quality, and facilitating zero-defect manufacturing. Additionally, broaching plays a crucial role in improving the quality of manufacturing products and processes. These aspects are especially pertinent in aeronautical manufacturing, which serves as the experimental case in this study.The research presents findings that establish a correlation between the variables of a broaching machine’s servomotors and the condition of the broaching tools. The authors propose an effective method for measuring broaching tool wear without external sensors and provide a detailed explanation of the methodology, enabling reproducibility of similar results. The results stem from three trials conducted on an electromechanical vertical broaching machine, utilizing cemented carbide grade broaching tools to broach a superalloy Inconel 718 test piece. The machine data collected facilitated the training of a set of machine learning models, accurately estimating tool wear on the broaches. Each model demonstrates high predictive accuracy, with a coefficient of determination surpassing 0.9.

Low-Cost Digitalization Solution through Scalable IIoT Prototypes

Industry 4.0 is fast becoming a mainstream goal, and many companies are lining up to join the Fourth Industrial Revolution. Small and medium-sized enterprises, especially in the manufacturing industry, are the most heavily challenged in adopting new technology. One of the reasons why these enterprises are lagging behind is the motivation of the key personnel, the decision-makers. The factories in question often do not have a pressing need for advancing to Industry 4.0 and are wary of the risk in doing so. The authors present a rapid, low-cost prototyping solution for the manufacturing companies with legacy machinery intending to adopt the Industry 4.0 paradigm with a low-risk initial step. The legacy machines are retrofitted through the Industrial Internet of Things, making these machines both connectable and capable of providing data, thus enabling process monitoring. The machine chosen as the digitization target was not connectable, and the retrofit was extensive. The choice was made to present the benefits of digitization to the stakeholders quickly and effectively. Indeed, the solution provides immediate results within manufacturing industrial settings, with the ultimate goal being the digital transformation of the entire factory. This work presents an implementation cycle for digitizing an industrial broaching machine, supported by state-of-the-art literature analysis. The methodology utilized in this work is based on the well-known DMAIC strategy customized for the specifics of this case study.

Investigation of the cutting fluid’s flow and its thermomechanical effect on the cutting zone based on fluid–structure interaction (FSI) simulation

Cutting fluids are an important part of today’s metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process state variables, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL-based cutting fluid simulation, but also pointed out the shortcomings of this method.

Design and Development of Broach Cleaning Mechanism

Broaching is most commonly used in industries for rapid and correct profiling of metal work piece. Broaching can be used to generate any desired shape by means of tool called broach. The profile that is largely produced is keyway and Splines. The keyways and splines are required in automotive components such as gears and pulleys. The closure relates to Design and development device used for cleaning broach tool compromising of a circular brush that rotate around the broach through a compressed air (Pelton Wheel turbine Like Mechanism) designed specifically for broaching machine to remove the metal chips accommodated in-between broach tool tooth and thus improve productivity of the broaching machine. A basic overview of burr formation and removal is presented in this paper. The main advantages, disadvantages, limitations, part quality and precision of these operations are presented.

Design and Development of Broaching Machine for Splines: A Case Study

Broaching machine is mainly developed for special purposes where cycle times are less and number of job quantity is very high. Only at such points development of broaching machine is justified. Design of such broaching machine is totally customizable. This paper discuss about frame design of machine, selection of guideways, design of hydraulic power pack for hydraulic operated machine and also selection of various cylinders, pipe fittings, mandrels, pump, motor, etc. So, main purpose of this paper is designing the broaching machine which includes all its components. This paper focuses on selection of bought out parts too.

Experimental investigation on reduction of broaching forces by active external vibrations

Broaching is very efficient for machining complex-shaped slots in turbine disks made of high thermal resistant super-alloys. However, large cutting forces and high thermal flux lead to high tool wear. To reduce the broaching forces, this paper proposes a vibration assisted broaching system, including the main components of a hydraulic horizontal internal broaching machine, an electrohydraulic vibration exciter, a 2-dimensional valve and a control unit. A force measuring structure and vibration signal acquisition module are designed and integrated into the system. By changing the frequency of the active vibration, cutting forces are obtained and analyzed by fast Fourier transformation method. The experimental results show that through the additional imposed vibration, static and dynamic broaching forces are significantly reduced.

Graphic modelling of the gear broaching process

The gear broaching method, in contrast to the hobbing methods with hob cutters, belongs to the shaping copying methods. The result of the gear broaching is a gear profile that is geometrically different from the theoretical design profile of the bevel gears. The possibility of graphical modeling of the results of the gear broaching process is currently absent, which makes it impossible to measure the geometric parameters of the rims of the gear wheels after their processing. The article proposes a method for graphical modeling of the process of gear broaching of bevel gears, including the construction of actual profiles of the broaching teeth, the adjustment scheme of the gear broaching machine, obtaining a family of trajectories of movement of each broaching tooth, aligning and stretching the profiles along the trajectories to obtain shaping elements. Subtraction of the shaping elements from the gear blank model produces a geometrically accurate 3D model of the bevel gear, which is the result of the interaction of each broach tooth and the blank.

Determination of the parameters of adjusting the gear broaching machine, according to the measurements of the spur bevel gears

The process of adjusting a gear broaching machine is considered, according to the angle of the cone of the depressions and the symmetry of the side profiles of the gear wheel. Standard adjustment methods do not allow measuring the values of the taper angle of the valleys and deviations from the symmetry of the profiles. The article proposes a method for finding the main setting parameters of gear broaching machine, according to the measurement data of spur bevel gears. The measurement method is implemented in the form of a measuring system, including a special control device equipped with inductive probes, and algorithms for processing their readings. The use of the measuring system makes it possible to increase the accuracy of setting up the gear traction machine and to improve the quality of manufacturing of spur bevel gears.

Penetration and lubrication evaluation of vegetable oil with nanographite particles for broaching process

With increasing environmental concerns, the substitution of mineral oil-based cutting fluid has become an urgent issue. Using vegetable soybean oil as base fluid, nanofluid cutting fluids (NFCFs) were prepared by adding different weight concentrations of nanographite particles (NGPs), and their penetration and lubrication performances were studied. A novel simulated tool-chip slit with micrometer-sized geometry was manufactured to evaluate and quantify the penetration rate of the NFCFs by image analysis approach. Moreover, a large number of comparative experiments on the closed-type broaching machine were carried out to compare the performance of the proposed NFCFs and a commercial cutting fluid in terms of cutting force, workpiece surface roughness, and metal chip. It is found that there is an optimal NGP concentration in NFCF for practical cutting applications. When the concentration of NGP is 0.4 wt%, the broaching process lubrication exhibits an ideal mixed lubricate state, resulting in minimal friction resistance, and thus, both the cutting force and chip curling angle reach their corresponding best values. Moreover, the proposed NGP-based vegetable-oil cutting fluid exhibits excellent environment-friendliness and low-cost consumption in the minimal quantity lubrication (MQL) method; this demonstrates its potential for replacing the traditional broaching cutting fluid.

Voltage- and Current-Measurement Based Force Estimation in Broaching Using Synchronous Motor Drive

Monitoring the cutting force in broaching provides valuable information about the tool condition as well as the effect of the process on the workpiece surface integrity. This study uses a synchronous-motor-drive broaching machine and deals with the motor-current based indirect-measurement of the cutting force, which is based on detecting the variation of the motor torque during cutting. Most current-based methods need to model the relationship between the motor current and the cutting force. However, when the feed drive mechanism is modeled to obtain this relationship, modeling errors occur. For accurate modeling, a calibration test using a force sensor is necessary before performing the indirect-force measurement. Therefore, this study focuses on the energy conversion from electrical power to mechanical power, and it identifies this relationship based on the voltage equation of the drive motor by using not only current measurement but also voltage measurement. Then, a developed model with the identified relationship calculates the cutting force, excluding electrical and mechanical losses that do not contribute to the process. By conducting a tool-wear test in broaching of Inconel 718, a possible application of the indirect force measurement system was demonstrated.

Analysis of the vertical moving table type broaching machine

Broaching is a type of machining that uses a toothed tool similar to a saw. There are several types of broaching machines includes linear broaching machines and hydraulic machines. Early linear broaching machines were driven mechanically by screws. However, hydraulic machines are faster, smoother in operation, and allow for high-speed steel broaches to be used. The purpose of this study is to an analysis of the vertical moving table type in the broaching machine. In this study, finite element analysis was carried out to examine the structural characteristics of broaching machine design. A model was created in CATIA software and analyzed with ANSYS to find the structural characteristics. The friction characteristic of PBT-40 material was also investigated. This material is recommended for guide rail surface lamination to reduce the friction coefficient and ram body wear. The simulation results provide information for the next step of development before physical prototype will be made. The maximum deformation of the workpiece table was 0.0517 mm on the positive Z-axis, and the maximum deformation on the pulling head device was 0.0598 mm on the negative Z-axis. The friction coefficients were between 0.013 and 0.047 in the sliding speed range of 0.06 to 0.34 m/s. The PBT-40 material has a wear coefficient of 1.604x10-13 m3/Nm according to the test. From the ANSYS friction simulation, it can be concluded that the PBT-40 material would not easily wear out during operation of the machine. It can be seen that small frictional stress occurred on the surface ranging from 8.273x10-5 to 8.381x10-5 MPa.

Effect of tool coatings on surface grain refinement in orthogonal cutting of AISI 4140 steel

Recrystallization mechanisms leading to the generation of ultrafine grains (UFG) by surface severe plastic deformation (S2PD) at low temperatures (< 0.5Tm (melting temperature)) have been investigated over the last years. Material removal processes like broaching impose large plastic strains along the shear plane during chip formation, leading in many cases to changes in the workpiece subsurface microstructure. In this work the influence of the cutting material on surface grain recrystallization were studied on broaching of AISI 4140q&t steel. Orthogonal cutting tests were carried out in dry conditions on a broaching machine using tools with different coatings. Uncoated cemented carbide inserts were geometrically prepared using fixed abrasive grinding processes and then coated by physical vapor deposition (PVD) with Al2O3 and CrVN thin films. Workpiece subsurface layers were analyzed after machining by Focused Ion Beam (FIB-SEM) and X-ray diffraction (XRD). The presented results show the influence of the cutting material on the final microstructure of the machined workpieces through the determination of the final grain sizes and dislocation densities.

Determination of Johnson-Cook material model parameters for AISI 1045 from orthogonal cutting tests using the Downhill-Simplex algorithm

Despite the increasing digitalization of manufacturing processes in the context of Industry 4.0, the process design and development of machining processes poses major challenges for today’s manufacturing technology. Compared to the conventional process design, which is influenced by an empirical "trial-and-error" principle, the simulative process design offers the possibility of reducing development time and costs while at the same time improving the process understanding. A possible simulation technique to achieve these goals is the Finite Element Method (FEM). The FEM enables the calculation of the thermo-mechanical load spectrum underlying the machining process. Therefore, different input models are required. One of the most critical input models is the material model, which describes the constitutive material behavior. To determine the material model parameters, either (conventional) material tests, which require an extrapolation into the regime of metal cutting, or inverse techniques are used, where the process itself is used as a material test. Using the inverse technique, the model parameters are modified iteratively until a predefined agreement between simulations and experiments is achieved. The evaluation of the agreement bases on integral process variables, such as the cutting force, and their simulative counterparts. However, the procedure of the inverse determination requires high computational efforts and is not robust. This paper presents a novel approach to enhance the robustness of the inverse material model parameter determination from the cutting process. Orthogonal cutting tests on AISI 1045 steel have been conducted on a broaching machine tool over a range of different cutting speeds and undeformed chip thicknesses to set an experimental database. Thereby, the workpiece material was investigated in the two different heat treatments: normalized and coarse-grain annealed. The machining experiments showed differences in terms of the integral process results when comparing the two heat treatments. These results motivated for the development of a methodology capable to determine material model parameters robust and inversely from the machining process, which can be used with lower computational effort. To simulate the machining process, a Coupled-Eulerian-Lagrangian (CEL) model of the orthogonal cutting process has been set up. The material model parameters have been inversely determined using the Downhill-Simplex-Algorithm, which has been modified for this case. By using the Downhill-Simplex-Algorithm, it was possible to determine material model parameters within 17 iterations and achieving an average deviation between the experiment and the simulations below 10 %. Thereby, different process observables such as temperature, forces, and chip form have been used for the evaluation. Through this method, it is possible to determine material model parameters, which enable a good match between experiments and simulations with a low computational effort.

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

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.

Tool-based inverse determination of material model of Direct Aged Alloy 718 for FEM cutting simulation

Direct aged Alloy (DA 718) has been widely used for aircraft engine components. FE-simulation of the cutting process of DA 718 can predict the process reliability regarding to the cutting force and the temperature. However, obtaining material and friction model for cutting simulation is still a challenge due to high strain, strain rate and temperature in shear zone. In this paper, a Coupled Eulerian-Lagrangian (CEL) FE-model has been applied to predict the cutting force and chip form in orthogonal cutting of DA 718. In order to obtain the material and friction model for the FE-model, an approach for inverse determination of the Johnson-Cook (JC) material model and the temperature-dependent friction model was applied. A software tool was programmed with Matlab to automatize this approach. By means of this software tool, experimental and simulative investigations of the friction behavior between carbide tool and DA 718 were conducted on a test bench on a broaching machine. A temperature-dependent friction model in tool-chip interface was determined. The parameters of the JC-material constitutive law and the JC-damage model were inverse determined by comparison of experimental and simulative results of cutting force, chip compression ratio and serration ratio in orthogonal cutting of DA 718. The FE-model with determined material and friction model was validated at different cutting speeds and feed rates with respect to cutting force and chip forms in orthogonal cutting.

Experimental and FEM analysis of surface integrity when broaching Ti64

The performance of aeronautic critical components is strongly dependent on its fatigue behavior, which is directly linked to their surface integrity condition. Broaching operation is a machining operation extensively used for the manufacturing of some features due to the good dimensional quality and surface integrity condition obtained. Thus, the characteristics of surface integrity obtained in broaching is a key aspect to be considered for the improvement of the fatigue life. This work proposes a Finite Element Method (FEM) model for the prediction of the surface integrity (material damage and residual stresses) of the workpiece obtained after the broaching process using the commercial finite element software DEFORM 2D. The model includes a self-characterized Johnson-Cook flow stress constitutive law for the titanium alloy Ti64. Experimental tests were carried out in an EKIN RAS 10x160x320 hydraulic broaching machine at different cutting conditions for the validation of the predictive model. Apart from the fundamental output variables, such as, forces and chip morphology, a comprehensive study of the surface integrity of the machined piece was done. The residual stresses generated by the cutting process were measured by the hole-drilling technique. Microstructural alterations (material damage) of the workpiece was analyzed by optical microscopy and Scanning Electron Microscope. Finally, the surface topography was examined by contact and optical profilometers. The results of the predictions showed significant good agreement with the experimental tests.

Development of a Servo-Based Broaching Machine Using Virtual Prototyping Technology

Predicting machine tool performance at the design stage is one way to resolve the time issue and achieve cost savings. The objective of this paper was to develop a new non-hydraulic broaching machine using a servo motor, ball screw, and roll element linear guide using virtual prototyping technology. First, we developed a multi-body simulation model (MBS) of a servo-based broaching machine to investigate its dynamic behaviour. Then, an adaptive sliding mode proportional-integral-derivative (PID)-based controller (ASMPID) was proposed to conduct the broaching process. We then performed a co-simulation between the mechanical structure and virtual controller to investigate the ram body trajectory and identify the optimal control parameters. Finally, we manufactured a prototype machine to evaluate the simulation results and determine the benefits of the new system. Our results indicated that the proposed model, which includes a mechanical structure and intelligent controller, effectively improved broaching machine design. Therefore, this work is expected to improve the prototyping efficiency of new broaching machines.