Thermomechanical compensation for hard broaching of thin wall components

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The aim of this research project is the development of a compensation method which, through a combination of distortion engineering and softsensor, enables a thermo-mechanical compensation of the hard broaching process to minimize workpiece distortion. The process chain for thin-walled internal gears, as used in electric powertrains, is chosen as the demonstration process. In the first phase, the distortion compensation potential through a thermomechanical actuator system will be investigated. This system applies thermal and mechanical point loads on the workpiece profile, which superimposes the loads generated by the broaching process. The effect of these loads means that the required target geometry is achieved after the component has cooled down and relieved. The effect of these loads means that the required target geometry is achieved after the component has cooled down and relieved. The existing distortions and distortion potential carriers are known. The compensation method should also take into account the initial state in the form of existing distortion and distortion potential carriers from previous process steps, as well as the process-inherent influence in the hard broaching process. The interactions between the component characteristics, the broaching process and the compensation system are identified and modelled leading to a mechanism-based metamodel able to predict and compensate the distortion generated by the broaching process.