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

本研究项目致力于开发一种整体的三维有限元仿真模型，以评估工艺与机械相互作用对零件质量的影响。基于在最初应用中开发的模拟方法，现在可以将模拟模型扩展到内拉削。首先，将进行实验研究，目的是分析生产过程，并最终验证所开发的模拟模型。为此，通过在全截面上进行单刀具试验，并将力的演变与特定的过程力的值进行比较，来评估微小切削刃对过程力的影响。在进一步的步骤中，通过交叉力分量对用于预测特定过程力的分析模型进行扩展，以能够计算所有作用力。这是必要的，因为直到工作的重点是外拉削，生产过程是用正交切割模拟的。为了能够尽可能准确地复制机床动力学，必须对机床如何与内置拉刀和夹具进行交互进行实验研究。将设置并验证机器模型。在下面的工作包中，机器模型将与用于计算比力的分析模型相联系。这两种模型的耦合将在两个界面上进行：工具-过程和过程-工件。然后，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。综上所述，所开发的模拟方法将示范应用于另一生产过程，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.