Solid Cemented High-Accuracy Surface Broaching Tool

Cutting operation and cutting tools is both the basis of manufacturing industry and the critical technique that influences the development of the important fields of manufacturing industry such as automobiles, household appliances, aerospace, energy and die-making.After around 100 year's rapid development, with the advancement in CNC machine. CNC system , tool materials and coating technology, etc., modern cutting techniques has entered into a new stage of high-speed cutting which is characterized by 5-10 times increase of cutting speed. With the introduction of high-speed cutting, the higher requirements for manufacturing industry is presented.Fisrt is high rigidity and accuracy of the machine itself; Second the high rigidity and accuracy of the clamping system; Third the good properties of tool materials and high machining accuracy;and the last, good cooling effect.With the development of cutting technique, the requirements for tool material is increasing.The traditional tool material tends to be replaced by material with better performace and to be widely used. For example, high-speed steel is to be replaced by fine-grain cemented carbide, cemented carbide to be replaced by ceramic and cermet.This is practical even for mass production.The application of PCD, CBN super-hard material is continously increased.Coating technology is widely used to improve the performance of tools.In material industry, newcomposite material is applied relative to different cutting operations to get better performance.Thanks to the development in both tool material and cutting technology, the the efficiency of different fields of cutting operation and different woking procedure of cutting operation and the general cutting technology as well are substantially improved; the cutting operation has entered into a new stage; a solid foundation has been laid for the development of manufacturing industry and manufacturing technique.Solid cemented carbide high-accuracy surface broaching tool is developed for machining the grooves on the vanes of air-conditioner compressor in this study, which representing the developing orientation of current tool materials and tools.Sub-micron cemented cabide tool with high geometrical accuracy and high position and shape accuracy is adopted for the investigation.A series of important works has done in the study. First, cemented carbide for making high accuracy surface broaching tool, which is suitable for machining alloy cast iron and easy for grinding is developed on the basis of advanced equipment and decades of experience in the development of cemented carbide materials; Second, the solid cemented surface broaching tool is designed after studying the design theory of broaching tool; Third, the pivotal grinding procedure is tested for solving the problem of manufacture accuracy and life of the tool. Forth, the broaching tool is tested and its structure and geometrical parameter is improved .According to the measurements of the surface broaching tool manufactured, the material performance, geometrical accuracy, tolerance of shape and position and surface roughness of the tool have come up to the standard of imported counterpart. With the same life time as that of the imported tool, this self-developed surface broaching tool has gained better economical benefits for the company.