Relevant bibliographies by topics / Broaching machine

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  1. Journal articles
  2. Dissertations / Theses
  3. Books
  4. Book chapters
  5. Conference papers

Academic literature on the topic 'Broaching machine'

Author: Grafiati
Published: 4 June 2021
Last updated: 1 February 2022

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Journal articles on the topic "Broaching machine"

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Park, Seok Hong, Duc Viet Dang, and Trung Thanh Nguyen. "Development of a Servo-Based Broaching Machine Using Virtual Prototyping Technology." Strojniški vestnik - Journal of Mechanical Engineering 63, no. 7-8 (July 17, 2017): 466. http://dx.doi.org/10.5545/sv-jme.2017.4384.

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Predicting machine tool performance at the design stage is one way to resolve the time issue and achieve cost savings. The objective of this paper was to develop a new non-hydraulic broaching machine using a servo motor, ball screw, and roll element linear guide using virtual prototyping technology. First, we developed a multi-body simulation model (MBS) of a servo-based broaching machine to investigate its dynamic behaviour. Then, an adaptive sliding mode proportional-integral-derivative (PID)-based controller (ASMPID) was proposed to conduct the broaching process. We then performed a co-simulation between the mechanical structure and virtual controller to investigate the ram body trajectory and identify the optimal control parameters. Finally, we manufactured a prototype machine to evaluate the simulation results and determine the benefits of the new system. Our results indicated that the proposed model, which includes a mechanical structure and intelligent controller, effectively improved broaching machine design. Therefore, this work is expected to improve the prototyping efficiency of new broaching machines.
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Lin, Lv Gao, Shen Shun Ying, Shu Qiong Chen, and Xiao Tian Lv. "Operational Modal Analysis of Broaching Machine." Applied Mechanics and Materials 159 (March 2012): 170–75. http://dx.doi.org/10.4028/www.scientific.net/amm.159.170.

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Modal parameters for LG51SH broaching machine from operational responses are studied to examine the dynamic properties of mechanical structure. The operational modal is analyzed using PolyMAX method with responsive data of key point in broaching machine, which is excited in practical broaching operation and tested by LMS SCADAIII-105 system. The identified steady state modal, representative modal shape, modal damping ratio and natural frequency in broaching are presented. The test and analysis result shows that there are natural frequency of 38Hz and 192Hz, which are close to multiple of the fundamental frequency of cutting force in broaching, 6Hz, therefore, reasonable cutting velocity should be adopted to void producing fundamental frequency of cutting force in broaching.
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Adiyanto, Okka, Park In Soo, Angga Senoaji Hermanto, and Choi Won Sik. "Analysis of the vertical moving table type broaching machine." Journal of Mechanical Engineering and Sciences 14, no. 3 (September 30, 2020): 7152–69. http://dx.doi.org/10.15282/jmes.14.3.2020.16.0561.

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Broaching is a type of machining that uses a toothed tool similar to a saw. There are several types of broaching machines includes linear broaching machines and hydraulic machines. Early linear broaching machines were driven mechanically by screws. However, hydraulic machines are faster, smoother in operation, and allow for high-speed steel broaches to be used. The purpose of this study is to an analysis of the vertical moving table type in the broaching machine. In this study, finite element analysis was carried out to examine the structural characteristics of broaching machine design. A model was created in CATIA software and analyzed with ANSYS to find the structural characteristics. The friction characteristic of PBT-40 material was also investigated. This material is recommended for guide rail surface lamination to reduce the friction coefficient and ram body wear. The simulation results provide information for the next step of development before physical prototype will be made. The maximum deformation of the workpiece table was 0.0517 mm on the positive Z-axis, and the maximum deformation on the pulling head device was 0.0598 mm on the negative Z-axis. The friction coefficients were between 0.013 and 0.047 in the sliding speed range of 0.06 to 0.34 m/s. The PBT-40 material has a wear coefficient of 1.604x10-13 m3/Nm according to the test. From the ANSYS friction simulation, it can be concluded that the PBT-40 material would not easily wear out during operation of the machine. It can be seen that small frictional stress occurred on the surface ranging from 8.273x10-5 to 8.381x10-5 MPa.
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Xu, Ming, Jing Ni, and Guo Jin Chen. "Research on the Broaching-Load Testing System of Hydraulic Broaching Machine." Advanced Materials Research 328-330 (September 2011): 1709–12. http://dx.doi.org/10.4028/www.scientific.net/amr.328-330.1709.

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In view of the disadvantages on working vibration or even cannot work of broaching machine derived by broaching-load’s uncertainty, a testing system of broaching-load is designed. The testing system uses an industrial computer, a high-precision data-acquisition-card, two pressure-sensors, a displacement-sensor and Borland C++ to test the broaching-load on the base of broaching machine’s electronic control system. The factual application in hydraulic broaching machine shows that the proposed system has a good performance on testing-accuracy. The proposed system gives an effective solution to broaching-load testing.
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Ying, Shenshun, Shiming Ji, Yangyu Wang, Zhixin Li, Lvgao Lin, and Sichang Xiong. "Experimental and numerical investigation on dynamic parameters of broaching machine." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 231, no. 10 (December 23, 2015): 1907–20. http://dx.doi.org/10.1177/0954406215623814.

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Dynamic properties of the whole broaching machine structure greatly contribute to the broaching quality and efficiency. However, it is hard to measure the dynamic parameters because they will change during operation compared with the static results from classic experimental modal analysis. This study is to examine the dynamic parameters of broaching machine LG7120KT using both the numerical finite element (FE) method and the experimental operational modal analysis (OMA). Firstly, FE analysis model of the broaching machine with the real dimension is constructed and calculated. Second, experimental results are obtained from OMA in practical broaching process, which can be used to identify steady-state modes. Modal parameters including mode shapes, damping ratio, and natural frequencies are examined, using both LMS SCADAS III-305 system and PolyMAX method in OMA. The numerical and experimental results show high agreement in their calculated natural frequencies. From the modal analysis results, it is also found the vibration normal to cutting direction can be greatly reduced by adjusting broaching speed. From the topology optimization result based on the already correlated FE model, we redesigned a lightweight machine structure with a better dynamic performance, due to its lower displacement of broaching machine at force point and its higher first-order natural frequency. The experimental and numerical results in this paper help to design the structural parameters of broaching machine and propose a better broaching process.
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Di, Shuan Hu, and Jin Yuan Tang. "Effects of a Keyway Broaching Machine Craft Parameters and Structural Parameters on Keyway Broaching Precision." Advanced Materials Research 871 (December 2013): 358–62. http://dx.doi.org/10.4028/www.scientific.net/amr.871.358.

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The 3D geometric model was established based on working principle of a new keyway broaching machine. The horizontal deformation of drawing knife blade in working stroke is analyzed by the finite element software ABAQUS. The research which effect law of the feed, structural sizes of cutter rod and sizes of cutter guiding rod on position deformation of broaching blade in working stroke given quantitative relationship between parameters of processing craft and structure and cutting precision. The selection method and way of processing parameters and structural parameters to improve broaching precision of keyway broaching machine are obtained. The research work provides relevant technological basis for the design of high precision keyway broaching machine.
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Chen, Guo Jin, You Ping Gong, Jing Ni, Tin Tin Liu, and Ming Xu. "Research on Structural Optimization Technology and Mechanical Dynamics for CNC Broaching Machine." Advanced Materials Research 700 (May 2013): 93–97. http://dx.doi.org/10.4028/www.scientific.net/amr.700.93.

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This paper takes the CNC broaching machine as the research object. The dynamic models for the various components of the broaching machine are established. The theories of the modal analysis and the dynamic performance are studied respectively. According to the analysis results, the improvement schemes on the partial structures or geometries are put forward. At the same time, the paper also studied preliminarily the dynamic characteristics of the CNC broaching machine. During the analysis process, the models of the parts and the whole model are established using the finite element method to optimize the structures of the parts and the whole. That has undoubtedly a very important significance for improving the dynamic performance of the new machines structure, improving the processing accuracy, shortening the development cycle and reducing the development costs.
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Chen, Guo Jin, Jing Ni, Ting Ting Liu, Ming Xu, and Lu Gao Lin. "Study on the Key Technology for Large-Scale High-Performance CNC Vertical Broaching Machine." Advanced Materials Research 705 (June 2013): 483–86. http://dx.doi.org/10.4028/www.scientific.net/amr.705.483.

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For the general broaching machines problems of structure bulkiness, poor cylinder synchronization, lack of optimization design, low-grade control system, low efficiency and operational reliability, the paper studied the structural optimization technology of the large-scale high-performance CNC vertical broaching machine, designed the new 360-degree high-load lateral rotary table, the axial-rotary multi-pass joint of the anti-leakage and the elastic-contact, and the modular slider rails, so as to improve the mechanical performance, the working stability and reliability. The remote network intelligent monitoring system and the multi-function data acquisition processor for the developed CNC broaching machine, realize the enterprise management information, the enterprise resource optimization, and the automation and intelligence of the manufacturing process.
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Chen, Guo Jin, Jing Ni, Ting Ting Liu, Ming Xu, and Lu Gao Lin. "Study on Structural Optimization and Servo Control for All-Electric CNC Broaching Machine." Applied Mechanics and Materials 380-384 (August 2013): 562–66. http://dx.doi.org/10.4028/www.scientific.net/amm.380-384.562.

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With respect to the conventional hydraulic broaching machine, the all-electric CNC broaching machine has many advantages. This paper combines the digital servo control system, the double ball screw and the linear motion rail to realize broaching for the two workpieces internal threads of the different rotations and lead distances. The DSP-based full-AC drive control system was developed. The observer is used to observe the speed instead of measuring the speed using the velocity sensor such as the encoder. It solves the drive control problems for the speed-sensorless servo-motors. That is in line with the trend of the CNC broaching machine technology toward the electronization, high-speed and preciseness.
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Tang, Y. J., Yang Yu Wang, S. M. Ji, X. Zhang, and Dong Hui Wen. "Experimental Investigation on the Dynamic Cutting Forces in Internal Broaching." Advanced Materials Research 215 (March 2011): 234–38. http://dx.doi.org/10.4028/www.scientific.net/amr.215.234.

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Cutting forces generated in broaching have a direct influence on the generation of heat, tool wear or failure, quality of machined surface and accuracy of the work piece. In this paper not only a cutting forces test scheme has been proposed but also a cutting forces measurement equipment has been designed with PCB 740B02 dynamical strain sensor and LMS SCADA III test system, respectively. Dynamical strain sensor was pasted on the cylinder type sensitive elements with which table and workpiece was connected. Experimental investigation on the dynamic cutting forces in the broaching direction of a hydraulic broaching machine had been carried out. Cutting forces measurement tests on Q235 steel workpiece material during broaching had been performed. Broaching in a variety of velocities, namely, 3.3m/min, 5m/min and 8m/min and in a variety of cutting depth, namely, 0.03mm, 0.04mm, 0.05mm and 0.07mm, were investigated. Output signal was analyzed both in time and frequency domains and the key characteristics of the cutting forces signal was obtained. Correlation between the frequency of broaching forces and the broaching velocity was also studied.
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Dissertations / Theses on the topic "Broaching machine"

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Tian, Wenmeng. "Monitoring and Prognostics for Broaching Processes by Integrating Process Knowledge." Diss., Virginia Tech, 2017. http://hdl.handle.net/10919/78680.

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With the advancement of sensor technology and data processing capacities, various types of high volume data are available for process monitoring and prognostics in manufacturing systems. In a broaching process, a multi-toothed broaching tool removes material from the workpiece by sequential engagement and disengagement of multiple cutting edges. The quality of the final part, including the geometric integrity and surface finish, is highly dependent upon the broaching tool condition. Though there has been a considerable amount of research on tool condition monitoring and prognostics for various machining processes, the broaching process is unique in the following aspects: 1) a broaching process involves multiple cutting edges, which jointly contribute to the final part quality; 2) the resharpening and any other process adjustments to the tool can only be performed with the whole broaching tool or at least a whole segment of the tool replaced. The overarching goal of this research is to explore how engineering knowledge can be used to improve process monitoring and prognostics for a complex manufacturing process like broaching. This dissertation addresses the needs for developing new monitoring and prognostics approaches based on various types of data. Specifically, the research effort focuses on 1) the use of in-situ force profile data for real-time process monitoring and fault diagnosis, 2) degradation characterization for broaching processes on an individual component level based on image processing; and 3) system-level degradation modeling and remaining useful life prediction for broaching processes based on multiple images.
Ph. D.
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Dvořák, David. "Testování a analýza protahovacího stroje." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2020. http://www.nusl.cz/ntk/nusl-417102.

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This master's thesis deals with the broaching technology. Theoretical part includes the essay about the technology, tools and machines used for broaching. Theoretical part also describes the analysis of the broaching machine testing. Practical part is focused on the collecting, comparing and analysis of the data. These data have been collected during and after the broaching process. The supplier of the new analysed broaching machine is Stenhoj Hydraulik and the older machine has been made by Arpini. The measurements show that the increased number of broached pieces influence the cutting force and the quality of the surface due to wear of the tool which has been also monitored. The measuring dimension through the ball is almost constant. In the conclusion we evaluated the economical aspect of the results.
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Mo, Shang Pin. "An experimental and finite element investigation of the broaching process." Thesis, University of Nottingham, 2001. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.368934.

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Rajam, Sham Kumar. "Design and finite element analysis of the broaching tools." Ohio : Ohio University, 1997. http://www.ohiolink.edu/etd/view.cgi?ohiou1177014495.

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Richards, Chad W. "A knowledge-based system for the design of round broaches." Ohio : Ohio University, 1989. http://www.ohiolink.edu/etd/view.cgi?ohiou1182458032.

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GUO, YU-YUN, and 郭玉芸. "Evaluation and analysis model of production data for broaching machine." Thesis, 2019. http://ndltd.ncl.edu.tw/handle/7d5zwg.

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碩士
國立勤益科技大學
工業工程與管理系
107
The raising broaching machine is the machine tools to process the surface and one-cut shape and it is the one of the most critical machine tools for processing the inner surface of the sprocket plate. The quality of the raising broaching machine directly affects the quality of the processed products; on the other hand, the quality of the processed products can be used to reflect the quality of the raising broaching machine. This study applies the six sigma quality index to establish a process quality level analysis chart that can simultaneously evaluate the quality characteristics of small-the-better (STB), large-the-better (LTB) and nominal-the-best (NTB) types. This analysis chart uses the accuracy index as the horizontal axis and the precision index as the vertical axis to evaluate if the quality level of the process quality, accuracy and precision meet the standard and finally aims at the quality characteristics to make the process improvement. Therefore, this analysis chart can not only help the broaching machine purchasers to analyze the quality of the processed products which are manufactured by the broaching machine and find the critical to quality (CTQs) needed to be modified for process improvement. Meanwhile, the related feedback is given to the broaching machine manufacturers to offer the better product design and reasonable tolerance design to confirm the quality level of the process and further advance the quality of tool machines for improving process capability and industrial competitiveness with the broaching machine purchasers.
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Books on the topic "Broaching machine"

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Iamaniże, Tʻ. Sangrevi instrumentisa da kʻanis urtʻiertʻkʻmedebis procʻesebis optimizacʻia. Tʻbilisi: "Mecʻniereba", 1995.

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K, Margulis D., and Ordinart͡s︡ev I. A, eds. Proti͡a︡zhki dli͡a︡ obrabotki otverstiĭ. Moskva: "Mashinostroenie", 1986.

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The World Market for Metal Broaching Machines: A 2004 Global Trade Perspective. Icon Group International, Inc., 2005.

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Parker, Philip M. The World Market for Metal Broaching Machines: A 2007 Global Trade Perspective. ICON Group International, Inc., 2006.

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Book chapters on the topic "Broaching machine"

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Huda, Zainul. "Broaching and Broach Design." In Machining Processes and Machines, 147–55. First edition. | Boca Raton : CRC Press, 2020.: CRC Press, 2020. http://dx.doi.org/10.1201/9781003081203-11.

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Faisal, Nadeem, Sumit Bhowmik, and Kaushik Kumar. "Recent Developments in Wire Electrical Discharge Machining." In Non-Conventional Machining in Modern Manufacturing Systems, 125–52. IGI Global, 2019. http://dx.doi.org/10.4018/978-1-5225-6161-3.ch006.

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The tremendous growth of manufacturing industries and desired need of accuracy and precision has put a great importance on non-traditional machining processes. Metal and non-metals having properties like high strength, toughness, and hardness is generally machined by non-conventional machining methods. One of earliest non-traditional machining that is still in use and being effectively utilized in industries is wire electrical discharge machine. This machining technique gives a tough line of competition to conventional machining process like milling, grinding, broaching, etc. Cutting intricate and delicate shapes with accuracy and precision gives this machining technique an edge over other conventional machining and non-conventional machining processes. This chapter provides an insight to various research and prominent work done in field of WEDM by various scientists, researchers, and academicians. The chapter also emphasizes various advantages and disadvantages of different modelling and optimization methods used. The chapter concludes with some recommendations about trends for future WEDM researchers.
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Conference papers on the topic "Broaching machine"

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Heer, Gurpreet Singh. "Design and Fabrication of Square Hole Drill Machine." In ASME 2007 2nd Frontiers in Biomedical Devices Conference. ASMEDC, 2007. http://dx.doi.org/10.1115/biomed2007-38015.

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Hole serves various purposes in any machine element. These holes may be round, square, rectangular or any other shape depending on the requirement. For round holes, the machines are available in the market. But for square or any other type of holes, the Methods presently used are broaching, electrode-discharge machine (E.D.M.), electro-chemical machine. These are very expensive and require special tools or machines.
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Ni, Jing, Bin Shao, and Guojin Chen. "Nonlinear PID synchro control on broaching machine with dual cylinder." In 2012 10th World Congress on Intelligent Control and Automation (WCICA 2012). IEEE, 2012. http://dx.doi.org/10.1109/wcica.2012.6358049.

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Tian, Wenmeng, Lee J. Wells, and Jaime A. Camelio. "Broaching Tool Degradation Characterization Based on Functional Descriptors." In ASME 2016 11th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/msec2016-8781.

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With rapid advancements in sensing technologies and computation capabilities, high-resolution machine vision data have become available for various manufacturing processes. For machining, the use of machine vision data has shown great promise in machining tool condition monitoring, a critical factor for final product quality. Extensive research has been performed on wear characterization using intensity-based methods, but limited work has made use of process knowledge for image processing phases. Additionally, previous work focuses on single cutting edge machining tools, but no methods have been proposed for multiple cutting edge machining tools, such as broaches. In this paper, a process knowledge-based image filtering method is proposed to eliminate within-image and between-image noise to obtain effective wear region(s) for each cutting edge on a broach. In addition, these wear regions across multiple cutting edges are jointly described by fitting their relationship with each cutting edge’s respective chip load. Finally, the extracted model parameters are used for unsupervised learning to determine the entire tool’s degradation levels from a training dataset. A case study is introduced to show the effectiveness of the proposed methodology using a hexagonal broach.
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Shenshun, Ying, Feng Minghui, Yuan Zhiying, and Lin Lvgao. "Design of a New-style Escort Mechanism of Vertical Internal Broaching Machine." In 1st International Conference on Mechanical Engineering and Material Science). Paris, France: Atlantis Press, 2012. http://dx.doi.org/10.2991/mems.2012.180.

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Guojin Chen, Jing Ni, Tingting Liu, Ming Xu, and Lugao Lin. "Study on structural optimization and servo control for all-electric CNC broaching machine." In 2012 4th Electronic System-Integration Technology Conference (ESTC). IEEE, 2012. http://dx.doi.org/10.1109/estc.2012.6485609.

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Bergs, Thomas, Benjamin Döbbeler, Tobias Seelbach, Martin Seimann, and Fritz Klocke. "Development of an Alternative Approach for Cutting Force Determination in Broaching." In ASME Turbo Expo 2019: Turbomachinery Technical Conference and Exposition. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/gt2019-90139.

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Abstract Fir tree slots in turbine discs are used as an attachment between the disc and the blades. To a great extend, these slots are manufactured by broaching. Currently, the used cutting tool material is High Speed Steel (HSS). Due to its low high temperature stability, the manufacturing process is limited to low cutting speeds (vc = 2–5 m/min) and presents, therefore, a bottleneck in the turbine manufacturing process. To increase the productivity, cemented carbide can be used as cutting tool material with cutting speeds up to five times higher than those used for HSS. Due to the high safety demands, the broaching process requires extensive process design to ensure a high process reliability. For the tool design, profound knowledge of the mechanical loads is mandatory due to its major effect on the manufactured part. Empirical research to investigate the actual mechanical load is time-consuming and expensive due to high tool costs, especially of cemented carbide broaches, and the high amount of possible tool geometry combinations. In this paper, an alternative approach to determine the cutting forces is presented. Grooving experiments were conducted in order to reproduce the engagement conditions from the broaching process. If the transferability of this approach can be shown, the amount of broaching tools as well as the availability of a broaching machine tool for the design of new broaching tools can be decrease dramatically. This would result in a reduction of tool design time and an increase in productivity for tool manufacturers.
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Bergs, T., U. Tombul, T. Herrig, A. Klink, and D. Welling. "Influence of an Additional Indexing Rotary Axis on Wire EDM Performance for the Automated Manufacture of Fir Tree Slots." In ASME Turbo Expo 2019: Turbomachinery Technical Conference and Exposition. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/gt2019-91505.

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Abstract The demand for higher efficiency in aircraft propulsion engines leads to materials with increasing thermo-mechanical strengths and new designs inducing filigree geometries of blisks and disks. Because of new designs which induce tighter tolerances, the high mechanical process forces in conventional cutting processes like broaching cause inacceptable geometrical deviations and high tooling costs. Due to the electro-thermal material removal mechanism, electrical discharge machining (EDM) ensures a force free and thus precise machining. The manufacture of fir tree slots in nickel-based alloys by wire EDM has been investigated in the last few years and the process was verified as an alternative technology for broaching. To get a better competitive position, the productivity can be prospectively increased by using an additional indexing rotary axis which ensures a precise and automated production of rotationally symmetric components and reduce production times e.g. for the manufacture of fir tree slots on a disk. Nevertheless, the application of these axes cause changed flushing conditions and can also affect the electrical contacting as well. Both influence the process performance and demand a technology development or adjustment of standard machining technologies. The influence of these changed machining conditions has not been investigated scientifically to date. In this paper, the surface integrity and process performance of fir tree slots machined by wire EDM on the machine table are compared with the manufacture by using an additional indexing rotary axis. The results of the investigations are supposed to create a basis for technology adaptions when using additional axes in wire EDM.
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Klocke, F., B. Doebbeler, M. Seimann, and M. Binder. "Towards High Productive Roughing of Profiled Grooves in Nickel Based Alloys." In ASME Turbo Expo 2016: Turbomachinery Technical Conference and Exposition. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/gt2016-56475.

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Facing a high demand for aircraft engines over the next decades in combination with new challenging materials, aircraft engine manufacturers are striving for new manufacturing processes. The manufacturing of profiled grooves for the mounting of the turbine blades on the disc is a bottle neck process today due to the exclusive use of High Speed Steel (HSS) tools in broaching. Because of the limited hot hardness of HSS, the applied cutting speeds are low compared to other conventional machining processes, i.e. 2–5 m/min. Furthermore, the broaching process has some more drawbacks regarding flexibility, capital commitment for machinery and tools as well as costs. Nevertheless, broaching offers outstanding properties regarding surface finish, manufacturing accuracy and is still a productive process due to the many cutting edges applied. There are some alternative process chains which are not yet in industrial use, which are able to substitute and/or complement the HSS-broaching process. In this paper, results are presented on two different roughing strategies for the manufacturing of profiled grooves in Nickel Based Alloys Allvac718plus and Inconel718. On the one hand, rough broaching with cemented carbide tools using indexable inserts was investigated at different cutting speeds, which are up to five times higher than the applied cutting speeds in industrial applications with HSS-tools. Two different carbide grades were investigated varying the cobalt content and the grain size. Cemented carbide is not state of the art in broaching Nickel Based Alloys due to its low fracture toughness. Different cutting edge inclination angles were applied and their effect on cutting forces, wear and tool chipping tendency were analyzed. On the other hand, rough side milling with ceramic cutting tools was investigated. Ceramic cutting tools excel in high hot hardness and thus can be used at very high cutting speeds i.e. up to 1000 m/min in Nickel Based Alloys. However, being very brittle and sensitive to alternating loads and thermal shock, machining processes with ceramic tools require extensive process design. In side milling experiments, Whisker reinforced as well as SiAlON and Oxide ceramic were investigated. In a first step, a window for machining parameters was identified. Then, tool life tests were conducted varying the feed at a fixed cutting speed of 1000 m/min. Subsequent to the experiments, the rim zone of the roughed grooves was investigated depending on the wear state of the used tools. The condition of the rim zone is a major criterion for the assessment of the adequacy of the roughing processes, because it can affect the subsequent finishing process. In further work, the interdependencies between the investigated roughing processes and finishing will be addressed.
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Klocke, F., T. Herrig, and A. Klink. "Evaluation of Wire Electrochemical Machining With Rotating Electrode for the Manufacture of Fir Tree Slots." In ASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/gt2018-76910.

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Components with best surface integrities — without any white layer or mechanically damaged rim zones — and regardless of mechanical properties of the material can be produced with electrochemical machining (ECM). Wire ECM combines the outstanding advantages of the ECM working principle with the kinematic of wire electrical discharge machining (wire EDM). A task-specific tool design — such as for classical sinking ECM — is not required for cutting 2.5-dimensional geometries like fir tree slots in turbine discs. Established manufacturing technologies for fir trees are broaching and recently wire EDM. However, high requirements on surface integrity of these turbine parts afford cost intensive finishing processes. Thus, wire ECM could be an attractive cost efficient alternative manufacturing process. Due to an insufficient flushing concept, a process development of wire ECM for fir tree slots with relevant disc heights failed in the past. A combination of an axial flushing with rotating structured electrode provides a promising approach to meet these challenges. Therefore, this paper presents investigations of cutting Inconel 718 direct-aged using the new flushing principle. Workpieces with heights up to 40 mm are machined, which is comparable to a low pressure turbine disc height. Reachable feed rates respectively cutting rates are presented. Due to the process specific edge rounding, the formation of the leading edges is examined. Finally, the evolving surface integrities with the help of surface roughness, cross sections and residual stresses are investigated and discussed.
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