Development of a combined simulation-model for the prediction of process- and machine-induced deviations of surface areas in broaching

本研究项目涉及开发一个整体的三维有限元仿真模型，以评估过程和机器的相互作用对部件质量的影响。基于最初应用中开发的仿真方法，现在可以将仿真模型扩展到内拉削。在开始，实验研究旨在分析生产过程，以及最终验证的模拟模型将开发进行。为此目的，次要切削刃对过程力的影响进行评估，进行测试与单切削刀具在整个部分，并比较力的演变，以特定的过程力的值。在另一步骤中，通过横向力分量来扩展用于预测特定过程力的分析模型，以能够计算所有作用的力。这是必要的，因为工作的重点是外拉削和生产过程模拟正交切削。为了能够尽可能准确地再现机床动力学，必须通过实验研究机床如何与内置内拉刀以及工件夹紧相互作用。将建立并验证机器模型。在以下工作包中，机器模型将与分析模型相关联，以计算比力。两个模型的耦合将发生在两个接口：刀具-工艺和工艺-工件。之后，将使用第一个工作包中生成的数据验证开发的模拟模型，并在必要时对其进行调整。总之，开发的模拟方法将被应用到另一个生产过程中，以评估方法的适应性。

This research project deals with the development of a holistic 3D-FEM-simulation model to assess the component quality influenced by the interactions of process and machine. Based on the simulation methodology developed in the initial application, it is now possible to extend the simulation model to internal broaching. At the begin, experimental studies aiming at analyzing the production process as well as finally validating the simulation model to be developed will be conducted. For this aim, the impact of minor cutting edges on process forces is evaluated by conducting tests with single-cutting tools in full section and comparing the force evolution to the values of the specific process forces. In a further step, the analytical model for predicting the specific process forces is extended by the cross force component to be able to calculate all the forces acting. This is necessary, since the work up to was focussed on external broaching and the production process was simulated with orthogonal cutting. To be able to replicate the machine dynamics as accurately as possible, it must be experimentally investigated how the machine interacts with the built-in internal broaching tool and the clamping of the workpiece. The machine model will be set up and validated. In the following work package, the machine model will be linked with the analytical model for calculating the specific forces. The coupling of the two models will take place at two interfaces: tool-process and process-workpiece. Afterwards, the developed simulation model will be validated with and if necessary adapted to the data generated in the first work package. In conclusion, the developed simulation methodology will be applied exemplarily to another production process in order to evaluate the methods adaptivity.