Figure - available from: The International Journal of Advanced Manufacturing Technology
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Schematic diagram of broaching process with complex profile tool. a Broaching process of turbine disk; b morphology of the curved shear zone; c characteristics of the curved shear zone
Source publication
Complex profile broaches are widely used in the manufacture of complex parts of aero-engines, but the forces in the broaching process are difficult to predict and control. A new numerical model for broaching force with complex profile tools was presented, which considered the area and arc length of the curved shear zone boundary. The area and arc l...
Citations
... Studies have established various cutting methods using geometric analysis tools. Ni et al. [16] used the finite element method to simulate shear band morphology at different cutting depths. The contact behavior and shear stress equation of a curved insert in the cutting process are different from those of conventional cutting tools. ...
... The rake face was in contact with the workpiece (Figure 3c); chips were generated in the contact zone between the rake face and nose radius. However, the undeformed cutting area of the curved insert changed during the cutting process, and the area of the shearing area gradually expanded [16]. The width of the chips generated because of this contact state increased with the increase in shear area. ...
Polytetrafluoroethylene (PTFE) is extensively used in equipment used for manufacturing semiconductor components and wet etching equipment. However, achieving ideal dimensional accuracy when cutting PTFE is challenging. In this study, we performed cutting experiments using a curvilinear tool and analyzed cutting force, cutting temperature, groove width, and surface roughness in PTFE grooving. The results indicated that the cutting force was most notably affected by the feed rate in Stage I of grooving. The rate of change in cutting force was the largest in Stage II because of the increase in the tool contact area. In Stage III, the shear area of the rake face was the largest, and the cutting force tended to be stable. The groove width was measured with a minimum error rate of 0.95% at a feed rate of 0.05 mm/rev. Moreover, the groove exhibited a time—independent springback. The minimum groove surface roughness was 0.586 at a feed rate of 0.05 mm/rev. The ideal feed rate was 0.05 mm/rev with groove width, surface quality, and chip curl as the key parameters. The processing parameters obtained in this study can be applied to actual production for the optimization of manufacturing accuracy.
