Numerical and experimental investigations on cutting force of broaching internal spline holes

摘要

Cutting force in broaching process is essential information for quality control, troubleshooting and tool life prediction, yet existing technical bottlenecks in prediction and acquirement in internal spline holes broaching process. Based on the mechanics of orthogonal metal cutting, a numerical model of the cutting force in internal spline broaching is constructed by Johnson-Cook material constitutive law and failure model taking friction on both rake face and flank face into consideration and is used to numerically estimate the cutting forces. A measurement apparatus is developed, and real-time cutting force is monitored, which contains the effects of structural vibration and can be divided into static cutting force and dynamic cutting force. Wavelet transform filtering method is therefore employed to separate the static component from dynamic component. Calculated value of the cutting force by numerical model is in good agreement with the static cutting force by experimental measurement. The model and measurement method are feasible in intelligent manufacturing where internal broaching process is used.