Optimization of broaching design

Broaching is one of the most recognized machining processes that can yield high productivity and high quality when applied properly. One big disadvantage of broaching is that all process parameters, except cutting speed, are built into the broaching tools. Therefore, it is not possible to modify the cutting conditions during the process once the tool is manufactured. Optimal design of broaching tools has a significant impact to increase the productivity and to obtain high quality products. In this paper, an optimization model for broaching design is presented. The model results in a non-linear non-convex optimization problem. Analysis of the model structure indicates that the model can be decomposed into smaller problems. The model is applied on a turbine disc broaching problem which is considered as one of the most complex broaching operations

Modelling High Speed Machining with the SPH Method

The purpose of this work is to evaluate the use of the Smoothed Particle Hydrodynamics (SPH) method within the framework of high speed cutting modelling. First, a 2D SPH based model is carried out using the LS-DYNA® software. SPH is a meshless method, thus large material distortions that occur in the cutting problem are easily managed and SPH contact control allows a “natural” workpiece/chip separation. The developed SPH model proves its ability to account for continuous and shear localized chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Then, The SPH model is used in order to improve the general understanding of machining with worn tools. At last, a milling model allowing the calculation of the 3D cutting forces is presented. The interest of the suggested approach is to be freed from classically needed machining tests: Those are replaced by 2D numerical tests using the SPH model. The developed approach proved its ability to model the 3D cutting forces in ball end milling

Metal cutting modelling SPH approach

The purpose of this work is to evaluate the use of the smoothed particle hydrodynamics (SPH) method within the framework of high speed cutting modelling. First, a 2D SPH based model is carried out using the LS-DYNA® software. The developed SPH model proves its ability to account for continuous and shear localised chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Then, the SPH model is used in order to improve the general understanding of machining with worn tools. At last, a hybrid milling model allowing the calculation of the 3D cutting forces is presented. The interest of the suggested approach is to be freed from classically needed machining tests: Those are replaced by 2D numerical tests using the SPH model. The developed approach proved its ability to model the 3D cutting forces in ball end milling

Identifying parameters of a broaching design using non-linear optimisation

Broaching is one of the most recognised machining processes that can yield high productivity and high quality when applied properly. One big disadvantage of broaching is that all process parameters, except cutting speed, are built into the broaching tools. Therefore, it is not possible to modify the cutting conditions during the process once the tool is manufactured. Optimal design of broaching tools has a significant impact to increase the productivity and to obtain high quality products. In this paper, an optimisation model for broaching design is presented. The model results in a non-linear non-convex optimisation problem. Analysis of the model structure indicates that the model can be decomposed into smaller problems. The model is applied to a turbine disc broaching problem which is considered as one of the most complex broaching operations