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

Person in Charge: Dipl.-Ing. Nikolay Boev

Motivation und Aims:

  • Highly efficient metal cutting process in the mass production
  • Components with high quality and for large mechanical loads
    Relatively simple dynamic properties
  • Influences on the quality of the machined parts by unwanted effects (vibration)
  • Development of a combined simulation-model for the prediction of process- and machine-induced deviations of surface areas in broaching


 

 

Research Results

Experimental process analysis:

  • Tool with a single tooth/multiple teeth

Simulation:

  • Variation of the cutting thickness and the cutting velocity
  • Variable cutting thickness and rake angle during broaching
  • Simulation of the dynamic behavior of the machine structure

Combined simulation model:

  • Machine model- string-dashpot-elements
  • Tool model – FEM
  • Process model – Regression functions

Experimental process analysis:

  • Surface profile
  • Roughness

Simulation:

  • Simulative prediction of process- and machine-induced deviations of surface areas in broaching