Measurement and modeling of geometric accuracy when broaching profile grooves

该项目的目的是开发一个整体模型，用于预测拉削安全关键发动机部件时可实现的形状和尺寸精度。当前航空工业发动机设计的技术发展导致更多的细丝结构，增加长宽比和更窄的形状和尺寸精度公差范围。前锉槽的拉削是涡轮盘生产中的关键工序。由于刀具的几何形状是固定的，因此不可能通过自适应过程控制来达到几何规格。利用经验确定的工艺数据，如特定的切削力分量，以及切削截面的几何渗透计算，通过数值模拟的方法预测发生的尺寸和形状偏差。基于要开发的整体模型，可以进行基于知识和模型的工具和工艺设计，以提高几何精度或继续满足由于当前发展而不断增加的公差要求。结果是一个系统的刀具几何和工艺设计模型，以满足轮廓几何及其功能曲面的几何要求。本项目研究了拉削过程中零件、刀具几何形状和工艺参数对型材槽形偏差的影响。通过对制造过程中导致型材槽形和位置偏差的弹性变形的研究和建模，为加工研究提供了新的质量保证和刀具设计模型和方法。

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.