Since 1968, as the demand for the broaching process has grown along with the availability of new materials, scientists and engineers have taken a keen interest in exploring the process's many ...scientific and technical challenges. In the last 56 years, people have been committed to solve the existing difficulties, mainly including the high stiffness and lightweight structure design of broaching machine, broaching technology of complex contour and fir-tree slot of difficult-to-machine materials for engines, green manufacturing technologies, workpiece surface monitoring in broaching processes, tool condition monitoring and life prediction, and so on. In this review, we focus specifically on the comprehensive development of broaching processes and equipment design over the past 56 years. We first review the basic principles of broaching and analyze the breakthrough progress in various research directions in broaching. In addition, we provide a detailed overview and discussion of broaching by keywords, year, country, journal, author and citation using bibliometric analysis for the first time. It is found that faced with the challenges in the field of broaching, researchers remain enthusiastic and have made significant contributions in areas such as process monitoring, equipment design, traditional broaching studies, and green manufacturing. It also gives new insights on the future development direction of broaching machine tools, i.e., in terms of future broaching high precision, intelligence, high efficiency and sustainability. We advocate for a deeper exploration of the broaching process and machine tool technology through extensive research, aiming to create expanded opportunities for scholars and engineers in this field.
•Review the basic principles of broaching and analyze the breakthrough progress in various research directions in broaching.•Provide a detailed overview of broaching in the last 56 years (1968–2023).•Discussion of broaching by keywords, year, country, journal, author and citation using bibliometric analysis.
Broaching is a key technology for the manufacturing of fir-tree slots. Due to the high-temperature-resistant materials used, a high mechanical load is applied to the workpiece during machining. ...Because of the filigree workpiece structure, the high mechanical load leads to a geometrical deviation of the machined webs which are formed by two consecutive fir-tree slots on the rotor circumference. Therefore, a methodology was developed to predict the resulting geometrical workpiece deviation. It was shown and validated in analogy experiments that the minimum achievable deviation is a function of the web geometry independent of the number of calibration cutters.
Broaching is a unique machining process with high accuracy and surface quality, which is employed in mass and batch production for the manufacture of components with highly complex geometries. It ...involves the use of multiple-edged complex tools in which the cutting edges are arranged with an offset also known as “rise per tooth” that determines the depth of cut per tooth. This paper presents the state-of-the-art of both the experimental and modelling aspects of broaching, and identifies the most important features related to this machining process. This includes a critical assessment of specifically designed broaching setups and their applicability and/or limitations compared to the machines used in industry. Contributions from academia and industry are included to support a comprehensive report of recent advances, as well as a roadmap for future developments.
This paper reviews work in geography concerned with the spatialities of “the subject” after non‐representational theory (NRT). The paper looks at what talking about “the subject” might refer to, ...particularly amid the aftermath of the decentering of the subject that took place in the latter part of the 20th century across the humanities and social sciences. The paper then provides an overview of the impacts that NRT has had on how geographers have understood and approached the subject. In particular, the paper focuses on recent work in human geography which takes the subject to be in some way emergent from encounters with various more‐than human others/alterity. Reflecting on that work, the paper broaches questions around difference and distribution. Here, a range of questions and lines of enquiry which might now be pursued in developing this work further are offered. These are summarised around the need for a “spacing” of the subject.
The increasing demand for medical prostheses, such as a dental prosthesis, leads to an increasing need for machining of CoCr alloys. The material properties of CoCr, such as high tensile strength, ...toughness, and wear resistance, are advantages for long-term use, but mean great challenges for machining. In this paper, the machinability of CoCr alloy varying cutting speed, rake angle and depth of cutting was investigated. Surface quality, cutting forces and chip shape were considered. The knowledge gained from the basic investigations can be used to increase tool life and improve productivity.
The concepts of memory, identity, and place form key debates in geographical literature because they link people to place. Memory incorporates narratives of the past that are articulated in the ...present day and can inform the way identities are constructed. The intersections of memory and identity can prompt us to think about how we experience and/or have experienced place(s). In this review, I trace discussions that position memory and identity as meta‐concepts that coalesce with the home and home‐building practices. I situate this discussion in and around the home because the home is commonly our most frequented place. It is a place where our person‐place bonds develop through everyday encounters and practices. I explore how memory, identity, and place have been broached in the home by using more‐than‐representational approaches. I have turned to more‐than‐representational theory to flesh out how enactments and encounters with objects and other materialities in the home demonstrate agency and connections to the home, which are indicative of memory and identity in action. Sensory and material encounters provoke remembrances and identifications with home(lands) through objects, people, food, and places that hold particular resonance among migrants.
Application of cutting fluids in broaching process plays a significant role in minimizing production cost and energy. However, conventional broaching fluids contain harmful and destructive chemical ...constituents, causing various environmental threats and operator hazards. Vegetable oil-based nano-cutting fluids are good alternatives owing to their less environmental threats, high thermal conductivity and supreme lubricating efficiency. The current study concentrates on the application of green vegetable oil-based cutting fluids in the broaching process. Firstly, conventional broaching oil (CBO) and five vegetable oils are proposed as cutting fluids. The sesame oil is preferred by analyzing the coefficient of friction (COF) and molecular structure of vegetable oils. Afterward, CuO, Al2O3, Fe3O4 and carbon powder nanoparticles were added into the sesame oil to prepare nanofluids. The CuO nanoparticle was selected to perform the further optimization because of its special particle shape and physical properties. Finally, the best concentration of CuO nanofluid, 0.54 wt%, was obtained by observing the distribution of nano-particles in the nanofluids. The results show that 0.54 wt% CuO nanofluid reduces the peak and trough loads amounted to 887 N and 774 N, respectively which are 62.7% and 68.6% higher than those of the pure sesame oil.
•Sesame oil could effectively reduce the broaching load.•CuO nano-particle has the best load reduction capability.•CuO nano-particle significantly reduces cutting energy consumption.•Within a certain limit, broaching nano-fluid lubrication effect increases with increasing concentration.•Optimum concentration of nano-particles stays at 160 mg with host fluid sesame oil.
Constructive measures in the design of aircraft engines aiming for CO2 and NOx emission reduction result in miniaturization of the components, e.g. the rotating turbine disks. The resulting filigree ...structures determine a reduction of the resistance against elastic workpiece deformations during the machining process. This leads to increasing demands on the cutting process to maintain the required form and position tolerances. In turbine disks, fir-tree slots as the fixing for the turbine blades are classified as safety-critical components. Currently, the profiled slots are manufactured by broaching. In order to guarantee the required component quality of the resulting fir-tree structure, it is necessary to examine the tool design systematically. By using FE simulations, it is possible to predict geometrical deviations after broaching and to perform counter measurements in tool design.
In this paper, an innovative approach is presented, which combines an empirical-analytical cutting force model and numerical FE simulations to model the elastic deformations during the cutting process. Therefore, empirical cutting force information are used as input data for the dynamic FE simulations. The results are then analyzed regarding the achievable form and position tolerances when broaching profile grooves. This paper presents a parameter study on workpiece and process parameters and an evaluation of their impact regarding the geometrical accuracy in broaching.
This paper aims to provide researchers and engineers with evidence that sensorless machine variable monitoring can achieve tool wear monitoring in broaching in real production environments, reducing ...production errors, enhancing product quality, and facilitating zero-defect manufacturing. Additionally, broaching plays a crucial role in improving the quality of manufacturing products and processes. These aspects are especially pertinent in aeronautical manufacturing, which serves as the experimental case in this study.
The research presents findings that establish a correlation between the variables of a broaching machine’s servomotors and the condition of the broaching tools. The authors propose an effective method for measuring broaching tool wear without external sensors and provide a detailed explanation of the methodology, enabling reproducibility of similar results. The results stem from three trials conducted on an electromechanical vertical broaching machine, utilizing cemented carbide grade broaching tools to broach a superalloy Inconel 718 test piece. The machine data collected facilitated the training of a set of machine learning models, accurately estimating tool wear on the broaches. Each model demonstrates high predictive accuracy, with a coefficient of determination surpassing 0.9.
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•Servomotor torque in broaching machines is strongly correlated to tool wear.•Machine learning models trained on servomotor data can accurrately estimate broaching tool wear.•A sensorless approach is possible for broaching tool indirect monitoring.
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