Force-based Temperature Modeling for Surface Integrity Prediction in Broaching Nickel-based Alloys

Klocke, Fritz; Gierlings, Sascha; Brockmann, Matthias; Veselovac, D.

doi:10.1016/j.procir.2014.04.053

Cited by 19 publications

(7 citation statements)

References 11 publications

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“…Result of the model beside the temperature distribution is the heat partitions between the relevant areas in the cutting zone. The model has been D DAVID PUBLISHING simplified and adapted for the broaching process by Gierlings [12]. Main disadvantages of the model are its limitation to the stationary state, the two dimensional considerations and the simplified cutting zone consisting of straight lines.…”

Section: State Of the Art mentioning

confidence: 99%

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Augspurger¹,

Peng²,

Klocke³

et al. 2018

JMEA

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Cutting super alloy is a highly sensitive manufacturing process regarding the complex thermo-mechanical interactions in the cutting zone, which finally determine the capability of the process in order to reach economic requirements. The connection between the intensity of heat sources as well as heat partitions into the tool, work piece and chip is yet not fully understood. Thus heat flows and other thermal conditions in the cutting zone cannot be predicted satisfactory, though they influence the chip formation mechanics, the surface integrity, respectively functionality of the machined work piece as well as the tool wear and lifetime. Because of this deficit the ecological and economical design of the manufacturing process is still limited and often not knowledge based. The proposed paper presents a methodology in order to measure and predict heat flows respectively affiliated temperatures during cutting nickel-base super alloy (Inconel 718). The heat flows in the cutting zone are determined by infrared thermography and a further energy balance by post processing the thermal images. A FE-model for chip formation simulation, which is based on CEL (Coupled-Eulerian-Lagrange) formulation, was used to calculate the heat flows. Finally, the results of the simulation and the experiments were compared.

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Section: State Of the Art mentioning

confidence: 99%

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Augspurger¹,

Peng²,

Klocke³

et al. 2018

JMEA

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“…Surface roughness obtained the average relative error of predicted roughness, and the measured roughness was 6.25% and 5.04%, respectively. Klocke et al [ 14 ] first conducted grinding experiments using nickel-based alloys. Secondly, they constructed a prediction model of processing parameters (grinding temperature, grinding pressure) and surface integrity based on experiments.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Surface Roughness of Abrasive Belt Grinding of Superalloy Material Based on RLSOM-RBF

et al. 2021

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It is difficult to accurately predict the surface roughness of belt grinding with superalloy materials due to the uneven material distribution and complex material processing. In this paper, a radial basis neural network is proposed to predict surface roughness. Firstly, the grinding system of the superalloy belt is introduced. The effects of the material removal process and grinding parameters on the surface roughness in belt grinding were analyzed. Secondly, an RBF neural network is trained by reinforcement learning of a self-organizing mapping method. Finally, the prediction accuracy and simulation results of the proposed method and the traditional prediction method are analyzed using the ten-fold cross method. The results show that the relative error of the improved RLSOM-RBF neural network prediction model is 1.72%, and the R-value of the RLSOM-RBF fitting result is 0.996.

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“…Optimization process of broaching and reaming tools is continuous and uninterrupted. In this respect, one can see some recent publications: a paper dedicated to geometrical optimization of broaching tool [3]; articles dedicated to the analysis of the distribution of forces in the process of holes machining [4][5][6]; U.S. Patent of a new broaching tool, about which there are many new patents issued every year concerning new designs of tools, and this particular patent is only an example of such a continuous process [7,8]. Articles dedicated to the analysis of the relationship of the cutting forces with the resulting surface quality.…”

Section: Introductionmentioning

confidence: 99%

Multiflute Drill-Broach for Precision Machining of Holes

Kasenov¹,

Dudak²,

Itybaeva³

et al. 2018

Scientia Iranica

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This paper deals with hole-enlarging multi-ute drilling process. In this respect, the analysis of existing structures, their advantages and disadvantages is carried out and investigated. Cutting conditions during hole-enlarging multi-ute drilling process are shown. Herein, a new design of a hole-enlarging multi-ute drilling, as a holeenlarging multi-ute drill-broaching tool from broaching-speed steel with carbide plates, and a new way of handling new tools are presented. Hole-enlarging multi-ute drillbroaching combines the features of hole-enlarging multi ute drill (in cross-section) and those of broaching tool (in longitudinal section). In so doing, it is possible to increase the quality of hole-making (size variance, surface roughness) to facilitate cutting conditions and increase durability. The results of prototypes testing are presented in the end.

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Force-based Temperature Modeling for Surface Integrity Prediction in Broaching Nickel-based Alloys

Cited by 19 publications

References 11 publications

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Prediction of Surface Roughness of Abrasive Belt Grinding of Superalloy Material Based on RLSOM-RBF

Multiflute Drill-Broach for Precision Machining of Holes

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