Measurement and modeling of geometric accuracy when broaching profile grooves

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The aim of the project applied for is the development of an integral model for the prognosis of the achievable shape and dimensional accuracy when broaching safety-critical engine components. Current technological developments in the design of engines for the aviation industry result in more filigree structures, increasing aspect ratios and narrower tolerance fields of the shape and dimensional accuracies. The broaching of pro-filed grooves is the critical process step in the production of turbine disks. Due to the fixed tool geometry, adaptive process control to achieve the geometric specifications is not possible. Using empirically determined process data, such as the specific cutting force components, and a geometric penetration calculation of the cutting cross-sections, the dimensional and form deviations that occur are predicted by means of numerical simulations. Based on the integral model to be developed, a knowledge and model-based tool and process design can be carried out with the aim of increasing the geometric accuracy or continuing to meet the increasing tolerance requirements due to current developments. The result is a design model for systematic tool geometry and process design to meet the geometric requirements of profile geometries and their functional surfaces. This project investigates the influences of component and tool geometry and process parameters during broaching on the shape deviations of profile grooves. By investigating and modelling the elastic deformation in the manufacturing process that leads to form and position deviations of the profile grooves, new models and methods for quality assurance and tool design are made available to machining research.