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The Study Of Cutting Wear And Mechanical Characteristics During The Broaching Process

Posted on:2019-06-28Degree:MasterType:Thesis
Country:ChinaCandidate:Z W WuFull Text:PDF
GTID:2371330548976525Subject:Mechanical engineering
Abstract/Summary:PDF Full Text Request
The technology of broaching,as a significant component of the modern industry system,has the properties of high efficiency,high precision and inexpensiveness.With the increasing process of the overall level of industrialization,a great number of researchers and practitioners devote themselves to the development of broaching equipment with high efficiency,high precision and better combination performance.However,the cutting wear is the most crucial factor.Therefore,it is of great significance to study the broaching cutters’ wear law and its affecting way to the broaching force in actual manufacturing practice,theoretically and practically.In view of the issues of cutting wear law and its influence to the broaching force,a research methed of the combination of the main cutting load on the rake surface and the friction load on the flank surface is presented.Meanwhile,orthogonal cutting theory and basic friction theory are introduced into the modeling process considering both of the variation of cutting area under the effect of cutting wear and the variation of wear area on the cutters’ flank surface.The model is also established with consideratoin of cutting periodical contact.Finally,the broaching tests are carried out based on the broaching system.The main research work and achievements of this paper are as follows:(1)The design of the keyway broaching wear testing system.According to the actual broaching condition and the requirement of the cutting wear test,the hardware part and software part are respectively considered.In detail,the basic structure of broaching machine,the broaching force detecting part,the electrical circuit,and the releted sensor selection are analyzed and designed.(2)The establishment of the broaching model considering the cutters’ wear.In terms of the orthogonal cutting theory and basic friction theory,the single tooth broaching model is established under the effect of cutting wear,and meanwhile,the variation of cutting area under the effect of cutting wear and the variation of wear area on the cutters’ flank surface are both taken into account.Finally,the broaching force model is established with consideration of cutting periodical contact.(3)The cutting wear experiment based on the keyway broaching system.with accordance to the testing program,the broaching experiment is carried out on the established broaching system.Focused on the actual broaching force variation law,the abrasion loss of the flank surface,the cutting-edge radius,and the workpiece surface roughness are respectively analyzed.(4)Broaching model computation and error analyzation.The numerical calculation of the established broaching model is realized with the utilization of MATLAB.And the existing errors of the experiment results are contrastively analyzed.Meanwhile,the main reasons of broaching wear and the variation of broaching force are objectively discussed.
Keywords/Search Tags:inner keyway slot broaching, cutting wear tests, real-time variation of cutting area, real-time variation of wear area, dynamic broaching load
PDF Full Text Request
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