Model-based analysis in finish broaching of inconel 718
Model-based analysis in finish broaching of inconel 718
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DOI：
10.1007/s00170-018-2221-5
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发表时间：
2018-05
期刊：
影响因子：
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通讯作者：
Martin Seimann;B. Peng;A. Fischersworring-Bunk;S. Rauch;F. Klocke;Benjamin Döbbeler
中科院分区：
文献类型：
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作者：
Martin Seimann;B. Peng;A. Fischersworring-Bunk;S. Rauch;F. Klocke;Benjamin Döbbeler
拉削仍然是制造涡轮盘异型槽的最先进技术。拉削过程可分为粗加工、半精加工和精加工。所制造的槽的功能性主要由与槽几何形状和表面完整性有关的精加工工艺决定。由于拉刀在精加工过程中与整个冷杉树槽接触，因此在精加工和半精加工过程中预计会产生最大的加工力。在特定几何形状的情况下，较高的加工力可能会导致工件材料变形，从而导致几何误差。涡轮盘拉削过程中的工艺和刀具设计主要基于经验。因此，通过基于经验的设计，例如采用新的刀具材料，如硬质合金拉刀，新的工艺和刀具设计既耗时又耗费成本。为了预测拉削过程中与槽型有关的过程力，本文引入了一个解析力模型和一个耦合欧拉-拉格朗日(CEL)方程的有限元模型。研究的参数范围是基于高速钢拉削的典型范围： =2.5m/min~5m/min，齿高h= 0.02 mm。通过这种新的基于模型的方法，可以在模型级别上设计和优化拉削工艺和刀具。
Broaching is still state of the art for manufacturing profiled slots in turbine discs. The broaching processes can be divided into roughing, semi-finishing, and finishing. The functionality of the manufactured slot is mainly determined by the finishing process with regard to the groove geometry and the surface integrity. Since the broaching tool is in contact with the entire fir tree slot in the finishing process, the highest process forces are expected in finishing and semi-finishing. In case of dedicate geometries, the high process forces can lead to the deformation of work piece material, and thus to geometrical inaccuracies. The process and tool design in turbine discs broaching processes are based mainly on experiences. Therefore, the new process and tool design are time- and cost-consuming by means of experiences-based design, for example, by implementation of new cutting material, such as carbide broaching tool. To predict the process forces in dependence on the slot geometry in broaching process, an analytical force model and a FEM model with coupled Eulerian-Lagrangian(CEL) formulation are introduced in this work. The investigated parameter range is based on the typical range for broaching with high speed steel forvc= 2.5 to 5 m/min, rise per toothh= 0.02 mm. By means of the new model based approach, the broaching process and tools can be designed and optimized on the model level.