Thermomechanical compensation for hard broaching of thin wall components

本研究项目的目的是开发一种补偿方法，该方法通过变形工程和软传感器的结合，使硬拉削过程的热机械补偿最小化工件变形。选择用于电力传动系统的薄壁内齿轮工艺链作为示范工艺。在第一阶段，将研究通过热机械致动器系统的变形补偿潜力。该系统在工件轮廓上施加热和机械点载荷，这叠加了拉削过程产生的载荷。这些载荷的影响意味着在组件冷却并解除后，可以实现所需的目标几何形状。这些载荷的影响意味着在组件冷却并解除后，可以实现所需的目标几何形状。已知现有的畸变和畸变势载体。补偿方法还应考虑到硬拉削过程中存在的变形和变形潜在载体的初始状态，以及过程固有的影响。对零件特性、拉削过程和补偿系统之间的相互作用进行了识别和建模，从而建立了一个基于机制的元模型，能够预测和补偿拉削过程产生的变形。

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.