Simulation Of Broaching Of FGH95 Nickel-base Superalloy And Optimization Of Broach Parameters

Over the past 30 years,the economy of China has experienced rapid development in different industries,especially the demand for the air transport industry is growing.Therefore,new materials,such as powder high temperature,applied to aircraft parts are constantly being researched and developed.The manufacture cycle of new materials is high-speed,the production volume is requirement,and the industrial department is increasingly demanding the processing of key core components to reduce the damage of parts and cause accidents.Furthermore,higher requirements are imposed on the use time and cost of the tool for machining parts.So,designing a suitable tool also has significance while ensuring the dimensional accuracy and surface quality of the machined parts.In this paper,a complete set of cemented carbide broach is designed for machining the tenon groove of turbine disk,and the effect of broaching parameters on the machining of powder superalloy FGH95 is studied by deform simulation software in order to optimize the geometric parameters of the tool.The cutting performance of the whole hard alloy broach is verified by field broaching test.Firstly,a new type of hard alloy material was used to prepare the whole solid carbide broach by the processing performance of nickel-based powder superalloy FGH95.Then,the broaching method and the common geometric parameters of the broach were selected according to the broaching process theory.And use 3D software to make a complete set of solid carbide broaches.Secondly,according to the theory of metal cutting and the foundation of finite element simulation technology,the finite element simulation model of broaching powder superalloy is established,and the cutting parameters(broaching speed,rise per tooth,tooth angles)are studied.The influence of tool geometry angle on cutting force,cutting temperature and tool wear.The calculation results in the post-processor are extracted and analyzed to optimize the geometric parameters of the roughing broach,the semi-finishing broach and the fine broach,as well as the broaching process to improve the surface quality.Finally,the single-factor test scheme was used to pulverize the nickel-based powder superalloy with the prepared solid carbide to study the effect of cutting speed on the surface roughness of the powder superalloy.Besides,scanning electron microscopy was used to observe the influence of inclusions introduced in the preparation process of powder superalloy on the surface morphology of the machined surface to select the appropriate broaching speed.The test results show that the broach made of the new cemented carbide material can cut the powder superalloy in a reasonable cutting speed range and obtaining process the high quality surface.Through simulation and experiment,it is shown that the finite element simulation technology is used to simulate the broaching process,and the force,temperature and tool wear law in the broaching process are analyzed,which plays an important role in optimizing the overall cemented carbide tool.The surface quality of nickel-based superalloy broaching with integral hard gold alloy broach meets the industrial requirements.