Analysis and optimisation of the hard broaching process with diamond tools
by Guilherme Evangelista Vargas, Konrad Wegener, Friedrich Kuster, Thomas Schnider
International Journal of Mechatronics and Manufacturing Systems (IJMMS), Vol. 1, No. 4, 2008

Abstract: Hard broaching is a finishing process to correct geometrical deviations of inner profiles on hardened work pieces, using a hardened steel body overlaid with a single layer of metal-bonded diamond grits. The process is characterised by a pendulum movement of the broaching tool. The tool consists of a conical roughing and a cylindrical finishing part. The finishing part increases the surface quality and reduces the tolerances. To get a deeper understanding of the process, and also for its optimisation, a stochastic model of the broaching tool was developed. The model-based analysis showed several suggestions for the improvement and optimisation of the hard broaching process, which have been experimentally verified in this work. With a modified pendulum strategy a relevant process time reduction of about 60% can be achieved.

Online publication date: Sat, 14-Feb-2009

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