چكيده به لاتين
Broaching is a metal cutting manufacturing process using a multiple edged tool to achieve desired geometries and high removal rates. The advantages of broaching are the machining of complex slot geometries within a single stroke. Thereby, high production rates, component accuracies and surface qualities can be achieved. Broaching is a widely used machining operation in the aerospace industry. In the first step of the thesis, broaching experiments have been carried out on AA7075-T651 aluminum alloy using different cutting speeds and cutting thickness with broaching needle and single edge cutting tool. In the next step, 2D cutting simulation approach was presented using the finite element method (FEM), which is applied in order to predict residual stress, cutting forces and its deviation from the mean while broaching. To investigate the influence of varying cutting speeds, cutting thicknesses, tool nose radius and rake angle the broaching process is simulated using the design of experiments (taguchi approach). The experimental results show that best surface roughness is obtained by cutting speed 12 m/min. The surface roughness will be improved by decreasing the rise per teeth. Also, the surface hardness decreases by increasing the cutting speed. The numerical results show that maximum residual stress increases by increasing cutting thickness and decreasing tool nose radius. Also, the cutting force increases by increasing cutting speed, cutting thickness, tool nose radius and decreasing rake angle.
Key words: Broaching, Residual stress, Cutting force, Surface roughness, Microhardness
