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

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

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