Wheel disc tenon and groove broaching force regulation method and system

Abstract

The present application relates to the turbine disc and compressor disc processing and manufacturing technical field of aero-engine, gas turbine, etc., and discloses a wheel disc mortise broaching force regulation and control method and system, the method comprises the following steps: obtaining broach geometric parameters, broaching process parameters and workpiece material physical properties; based on the broach geometric parameters, the broaching process parameters and the workpiece material physical properties, the shear flow stress on the main shear surface in the cutting process is calculated, and the cutting force considering the strain softening and temperature-strain rate coupling effect is further calculated; based on the broach geometric parameters and the shear flow stress, the edge extrusion force caused by the broach edge roundness radius is calculated; the broaching force and the edge extrusion force are superimposed to obtain the wheel disc mortise broaching force; according to the wheel disc mortise broaching force, the broach geometric parameters and the broaching process parameters are adjusted and controlled, and then the wheel disc mortise broaching force is optimized to meet the actual processing requirements, which provides support for reducing the tool optimization design cost and improving the wheel disc processing quality.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of turbine disc and compressor disc machining and manufacturing of aero-engines, gas turbines and the like, and particularly relates to a wheel disc mortise broaching force regulation method and system. BACKGROUND

[0002] Broaching is a key process in the mortise manufacturing process of turbine disc and compressor disc (referred to as wheel disc) of aero-engines, gas turbines and the like. The broach is the core tool for broaching mortises, and its geometric parameters are basically determined in the design stage. However, the fluctuation of the wheel disc mortise broaching force in the broaching process has a significant impact on the workpiece size accuracy, surface integrity and tool life. Therefore, establishing an accurate wheel disc mortise broaching force regulation method not only helps to improve the accuracy of evaluating the influence of broach structure parameters on machining quality, but also can be used to regulate tool design parameters and broaching process parameters to improve machining quality. The traditional mortise broaching force calculation method does not fully analyze and calculate the effects of workpiece material strain softening, temperature-strain rate coupling effect and blade edge corner radius of the broach on the blade edge extrusion force, resulting in a large deviation between the calculation results and the measured values, which makes it difficult to guide the broaching force regulation and improve the wheel disc mortise machining quality. SUMMARY

[0003] The purpose of the embodiments of the present application is to provide a wheel disc mortise broaching force regulation method and system, aiming to solve the problem of how to improve the accuracy of wheel disc mortise broaching force calculation results, improve the accuracy of evaluating the influence of broach structure parameters on machining quality, reduce the cycle and cost required for optimizing tool design parameters and broaching process parameters, and provide support for improving wheel disc machining quality.

[0004] According to a first aspect of the embodiments of the present application, a wheel disc mortise broaching force regulation method is provided, comprising:

[0005] (1) acquiring broach geometric parameters, broaching process parameters and workpiece material physical properties, wherein the broach geometric parameters include a rake angle γ0, a blade corner radius r e , a tooth rise t1, a tooth width w, a cutting area S; the broaching process parameters include a broaching speed V, an inclination angle θ S of the wheel disc mortise, a coolant temperature T C ; and the workpiece material physical property parameters include: a density ρ, a specific heat capacity Cp, a thermal conductivity K, a melting point T m , a tool chip friction coefficient μ, a yield stress A, a hardening constant B, a strain rate constant C, a hardening index n, a thermal softening index m, an initial yield stress σ0, a steady yield stress σ s , a reference strain rate a strain coefficient r, and a strain rate coefficient D;

[0006] (2) calculating the shear flow stress on the main shear surface in the cutting process based on the broach geometric parameters, the broaching process parameters and the physical properties of the workpiece material, and further calculating the cutting force considering the strain softening and the temperature-strain rate coupling effect;

[0007] (3) calculating the edge extrusion force caused by the broach edge roundness radius based on the broach geometric parameters and the shear flow stress;

[0008] (4) superimposing the broaching force and the edge extrusion force to obtain the wheel disc mortise broaching force;

[0009] (5) adjusting and controlling the broach geometric parameters and the broaching process parameters according to the wheel disc mortise broaching force, and further optimizing the wheel disc mortise broaching force to meet the actual machining requirements.

[0010] Further, step (2) comprises:

[0011] (2.1) calculating the friction angle β and the initial shear angle based on the tool-chip friction coefficient μ and the broach rake angle γ0, and optimizing based on the initial shear angle to obtain the final shear angle

[0012] (2.2) calculating the shear strain γ and the shear strain rate based on the broach rake angle γ0, the broach tooth rise t1, the broaching speed V and the shear angle

[0013] (2.3) calculating the shear strain γ and the shear strain rate based on the broach tooth rise t1, the broaching speed V, the density ρ, the specific heat capacity Cp, the thermal conductivity K, the melting point T m , the yield stress A, the hardening constant B, the strain rate constant C, the hardening index n, the thermal softening index m, the initial yield stress σ0, the steady yield stress σ s , the reference strain rate , the strain coefficient r, the strain rate coefficient D, the coolant temperature T C and the shear strain γ and the shear strain rate , under the premise of a given initial shear force F s0 , gradually correcting the shear stress τ s to obtain the final shear flow stress τ s ;

[0014] (2.4) calculating the cutting force in the broaching direction, the feed direction and the direction perpendicular to the broaching plane F S based on the broach rake angle γ0, the broach tooth rise t1, the broach tooth width w, the inclination angle θ s of the wheel disc mortise, and the friction angle β, the shear angle cF t and F P .

[0015] Further, step (2.1) includes:

[0016] Using the chip friction coefficient μ and the broach rake angle γ0, the friction angle β and the initial shear angle are calculated by equations (1) and (2).

[0017] β=arctanμ (1)

[0018]

[0019] By combining formulas (3), (4), and (5) and solving iteratively, the final shear angle can be obtained.

[0020]

[0021]

[0022] Where C n θ is the strain hardening exponent, and θ is an intermediate variable.

[0023] Furthermore, in step (2.2), the shear strain γ and shear strain rate are calculated using formulas (6) and (7).

[0024]

[0025]

[0026] Where q is the coefficient describing the non-uniform distribution characteristic of the tangential velocity in the first deformation zone. This is the shear angle.

[0027] Furthermore, in step (2.3), the shear strain γ and shear strain rate calculated in step (2.2) are... Given an initial shear force F s0 Under the premise of this, the shear stress τ is gradually corrected using equations (8) to (9). s When τ si -τ si-1 When the stress is less than a predetermined threshold, the final shear flow stress τ is determined. s :

[0028]

[0029] Where η is the proportionality coefficient for the conversion of shear energy into enthalpy, and ξ is the heat distribution coefficient.

[0030] Furthermore, in step (2.4), based on the broach rake angle γ0, broach tooth rise t1, broach tooth width w, and the inclination angle θ of the wheel mortise, S And the friction angle β and shear angle calculated in step (2.1) The shear flow stress τ obtained in step (2.3) s The cutting force component F is calculated using formula (11). c F t and F P :

[0031]

[0032] Furthermore, in step (3), the components P of the cutting edge extrusion force in the broaching direction, the feed direction, and perpendicular to the broaching plane are calculated using formula (12). c P t With P P :

[0033]

[0034] Where ψ is the angle between the material separation point on the cutting edge and the vertical direction, and τ s This refers to shear flow stress.

[0035] Further, in step (4), the components of the broaching force and the cutting edge extrusion force in the broaching direction, the feed direction, and perpendicular to the broaching plane are superimposed using formula (13) to obtain the corresponding component of the wheel mortise broaching force F, and then the wheel mortise broaching force F is obtained according to formula (14):

[0036]

[0037] Among them, F c F t and F P P represents the components of the cutting force in the broaching direction, feed direction, and perpendicular to the broaching plane. c P t With P P It is the component of the cutting edge extrusion force in the broaching direction, the feed direction, and perpendicular to the broaching plane.

[0038] According to a second aspect of the embodiments of this application, a wheel tenoning force adjustment system is provided, comprising:

[0039] The data acquisition unit is used to acquire broach geometry parameters, broaching process parameters, and workpiece material physical properties, wherein the broach geometry parameters include the rake angle γ0 and the cutting edge fillet radius r. e Tooth rise t1, tooth width w, cutting area S; broaching process parameters include broaching speed V, and the inclination angle θ of the wheel groove. S, coolant temperature T C ; the workpiece material physical property parameters include: density p, specific heat capacity Cp, thermal conductivity K, melting point T m , tool chip friction coefficient mu, yield stress A, hardening constant B, strain rate constant C, hardening index n, thermal softening index m, initial yield stress sigma0, steady yield stress sigma s , reference strain rate Strain coefficient r, strain rate coefficient D;

[0040] A cutting force calculation unit for calculating the shear flow stress on the main shear surface during cutting based on the puller geometric parameters, process parameters and workpiece material physical properties, and further calculating the cutting force considering strain softening and temperature-strain rate coupling effect;

[0041] A blade extrusion force calculation unit for calculating the blade extrusion force caused by the puller blade corner radius based on the puller geometric parameters and the shear flow stress;

[0042] A wheel disc slot broaching force calculation unit for superimposing the broaching force and the blade extrusion force to obtain the wheel disc slot broaching force;

[0043] A wheel disc slot broaching force regulation unit for adjusting and controlling the puller geometric parameters and broaching process parameters according to the wheel disc slot broaching force, and further optimizing the wheel disc slot broaching force to meet the actual machining requirements.

[0044] Further, it further comprises:

[0045] A data storage unit for storing the wheel disc slot broach structure parameters, workpiece material parameters, broaching process parameters and wheel disc slot broaching force calculation results.

[0046] The technical scheme provided by the embodiment of the present application can include the following beneficial effects:

[0047] As can be seen from the above embodiments, the present application calculates the cutting force component caused by strain softening and temperature-strain rate coupling and the blade extrusion force component caused by the puller blade corner radius, thereby significantly improving the accuracy of wheel disc slot broaching force calculation and reducing the deviation from the measured value. Through this method, not only the accuracy of evaluating the influence of puller structure parameters on machining quality is improved, but also the cost of low tool optimization design is reduced and the wheel disc machining quality is improved.

[0048] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. BRIEF DESCRIPTION OF DRAWINGS

[0049] The accompanying drawings, which are incorporated herein and constitute part of the specification, illustrate embodiments consistent with the application and, together with the description, further serve to explain the principles of the application.

[0050] Figure 1 is a flow chart of a wheel disc mortise broaching force regulation method according to an exemplary embodiment.

[0051] Figure 2 is a broaching force prediction comparison chart according to an exemplary embodiment.

[0052] Figure 3 is a block diagram of a wheel disc mortise broaching force regulation system according to an exemplary embodiment.

[0053] Figure 4 is a schematic diagram of an electronic device according to an exemplary embodiment. DETAILED DESCRIPTION

[0054] The exemplary embodiments will be described in detail herein with reference to the accompanying drawings. In the following description, unless otherwise indicated, like numbers in the different drawings represent similar or analogous elements. The following exemplary embodiments described in this specification are not meant to represent all implementations in keeping with the present application.

[0055] The terminology used in the present application is for the purpose of describing particular embodiments only and is not intended to be limiting of the present application. As used in the present application and the appended claims, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0056] It should be understood that, although the terms first, second, third, etc. can be used herein to describe various information, these terms are not intended to denote a particular order or hierarchy. These terms are used only to distinguish one from another. For example, a first information can be termed a second information, and, similarly, a second information can be termed a first information, without departing from the scope of the present application. As used herein, the word "if' can be interpreted to mean "when" or "upon" or "in response to determining" taking into account the context in which the term is used.

[0057] The present application provides a wheel disc mortise broaching force regulation method, as shown in Figure 1 specifically comprising the following steps:

[0058] Step (1): obtaining broach geometry parameters, broaching process parameters, and workpiece material physical properties, wherein the broach geometry parameters include rake angle γ0, blade corner radius r e, tooth rise t1, tooth width w, cutting area S; broaching process parameters include broaching speed V, wheel disc mortise angle θ S , cooling liquid temperature T C ; workpiece material physical property parameters include: density p, specific heat capacity Cp, thermal conductivity K, melting point T m , tool chip friction coefficient mu, yield stress A, hardening constant B, strain rate constant C, hardening index n, thermal softening index m, initial yield stress sigma0, steady yield stress sigma s , reference strain rate Strain coefficient r, strain rate coefficient D;

[0059] Specifically, according to the broach design drawing, the geometric parameters of the front angle gamma0, the tooth rise t1, the tooth width w, the cutting area S, and the wheel disc mortise angle theta S are obtained; the tool edge roundness radius r e is measured by an instrument; the broaching speed V and the cooling liquid temperature T C are set in the numerical control system; the workpiece material physical properties are obtained through experiments and literature review, including: density p, specific heat capacity Cp, thermal conductivity K, melting point T m , tool chip friction coefficient mu, yield stress A, hardening constant B, strain rate constant C, hardening index n, thermal softening index m, initial yield stress sigma0, steady yield stress sigma s , reference strain rate Strain coefficient r, strain rate coefficient D.

[0060] In an embodiment, the obtained parameters are shown in Table 1 in detail.

[0061] Table 1 Input parameter table

[0062]

[0063] Step (2): Based on the broach geometric parameters, broaching process parameters and workpiece material physical properties, the shear flow stress on the main shear surface in the cutting process is calculated, and the cutting force considering strain softening and temperature-strain rate coupling effect is further calculated;

[0064] Specifically, this step can include the following sub-steps:

[0065] (2.1) Determine the friction angle beta and the shear angle

[0066] Using the tool chip friction coefficient mu and the broach front angle gamma0, first calculate the friction angle beta (the angle between the tool rake face and the chip) and the initial shear angle (the angle between the shear plane and the cutting speed direction) by formulas (1) and (2). Then, formulas (3), (4) and (5) are solved by iteration to obtain where C n is the strain hardening exponent, θ is an intermediate variable, and the iteration termination condition is set as less than 0.001.

[0067] β = arctan μ (1)

[0068]

[0069]

[0070] (2.2) Determining the strain γ and shear strain rate on the main shear plane during the cutting process

[0071] The collected broach rake angle γ0, broach tooth lift t1, broach speed V, and the shear angle θ calculated in the foregoing are substituted into equations (6) to (7) to calculate the shear strain γ and shear strain rate where q is a coefficient describing the tangential velocity non-uniform distribution characteristics of the first deformation zone, and for processing plastic materials, q = 3 at low speed and q = 7 at high speed.

[0072]

[0073] (2.3) Determining the average cutting temperature T on the main shear plane during the cutting process AB and shear flow stress τ s .

[0074] Based on the collected broach tooth lift t1, broach speed V, density ρ, specific heat capacity Cp, thermal conductivity K, melting point T m , yield stress A, hardening constant B, strain rate constant C, hardening exponent n, thermal softening exponent m, initial yield stress σ0, steady-state yield stress σ s , reference strain rate strain coefficient r, strain rate coefficient D, coolant temperature T C , and the shear strain γ and shear strain rate calculated in step (2.2) Under the premise of a given initial shear force F s0 , the shear stress τ s is gradually corrected using equations (8) to (9), and when τ si - τ si-1 is less than 0.001, the final shear flow stress τ s is determined. The heat distribution coefficient ξ is determined by equation (8). η is the proportionality coefficient for converting shear energy into enthalpy, and η is usually taken as 0.9.

[0075]

[0076] ​(2.4) Calculate the cutting force considering strain softening and temperature-strain rate coupling effects, including the cutting force in the broaching direction (broaching X-axis), the feed direction (broaching Z-axis), and the vertical direction perpendicular to the broaching plane (broaching X-Z-axis plane) F c , F t , and F P .

[0077] Based on the collected broach rake angle γ0, broach tooth rise t1, broach tooth width w, wheel disc mortise inclination θ S , and the friction angle β and shear angle calculated above, the shear flow stress τ s , the cutting force components F c , F t , and F P can be further calculated by formula (11).

[0078]

[0079] The above calculation method of broaching force effectively solves the problem that the traditional broaching force calculation method does not fully consider the strain softening and temperature-strain rate coupling effects, making the real deformation behavior of the material in the metal cutting process more accurate modeling, and the broaching force calculation more accurate.

[0080] Step (3): Based on the broach geometric parameters and the shear flow stress, calculate the blade edge extrusion force caused by the broach blade edge roundness radius;

[0081] Calculate the blade edge extrusion force caused by the broach blade edge roundness radius, including the force in the broaching direction (broaching X-axis), the feed direction (broaching Z-axis), and the vertical direction perpendicular to the broaching plane (broaching X-Z-axis plane) P c , P t , and P P .

[0082] Based on the collected broach width w, broach roundness radius r e , and the shear flow stress τ s calculated above, the blade edge extrusion forces P c and P t can be further calculated by formula (12). Where ψ is the angle between the material separation point on the cutting edge and the vertical direction, and the value is 14°.

[0083]

[0084] The above calculation method of broaching force effectively solves the technical problem that the broaching force modeling in the traditional broaching process cannot accurately represent the blade edge effect, making it possible to quantitatively evaluate the mechanical effect caused by the mortise broach blade edge roundness.

[0085] Step (4): superimposing the broaching force and the edge extrusion force to obtain the wheel disc mortise broaching force;

[0086] The wheel disc mortise broaching force F is calculated, including calculating the components F V , F H and F R in the broaching direction (the broaching machine X axis), the feeding direction (the broaching machine Z axis) and the direction perpendicular to the broaching plane (the broaching machine X-Z axis plane). c , F t and F P are substituted into formula (13) to calculate F c , F t and F P . The wheel disc mortise broaching force F can be further calculated through formula (14). V , F H and F R .

[0087]

[0088] The wheel disc mortise broaching force calculation method constructed in step (4) can accurately reflect the change of the wheel disc mortise broaching force in the broaching process by synthesizing the force components of the cutting force (F c , F t and F P ) and the edge extrusion force (P c , P t and P P ) in the broaching direction and the feeding direction, effectively solves the problem of large deviation in broaching force prediction caused by ignoring the edge effect in the traditional model, and improves the calculation accuracy of the broaching force.

[0089] In this embodiment, after obtaining the parameters shown in Table 1 above, the broaching force modeling and calculation are sequentially performed according to steps (2) to (4), and finally the broaching force prediction result is obtained, as shown in Table 2. Figure 2 The results show that the prediction result of the method in the present application by introducing the edge extrusion force improves the broaching force prediction accuracy by about 10% compared with the traditional method which does not consider the workpiece material strain softening, the temperature-strain rate coupling effect and the edge extrusion force, verifying the effectiveness and engineering adaptability of the method in the present application under actual machining conditions.

[0090] Step (5): adjusting and controlling the broach geometric parameters and the broaching process parameters according to the wheel disc mortise broaching force, and then optimizing the wheel disc mortise broaching force to meet the actual machining requirements.

[0091] In actual broaching process, excessive broaching force can cause many problems, such as machining deformation, tool wear, and machining surface quality decline, etc. If the broaching force is too small, it cannot effectively remove the material, cannot achieve the expected machining size and precision requirements, and also reduces the machining efficiency. Therefore, according to the specific structure of the wheel disc mortise and tenon, the material properties, the machining requirements and other factors, the adjustment range of the tool design parameters and the broaching process parameters is analyzed and controlled, and the wheel disc mortise and tenon broaching force calculated by step (4) is controlled to adjust the tool design parameters and the broaching process parameters, so as to improve the machining quality of the wheel disc mortise and tenon. In this embodiment, the surface roughness value of the mortise and tenon can be improved from Ra1.6 to Ra0.8 or more through the above steps, which verifies the effectiveness and engineering adaptability of the method under actual machining conditions.

[0092] Corresponding to the foregoing embodiments of the wheel disc mortise and tenon broaching force regulation method, the present application also provides embodiments of a wheel disc mortise and tenon broaching force regulation system.

[0093] Figure 2 is a system block diagram according to an exemplary embodiment. Referring to Figure 2 , the system can include:

[0094] A data acquisition unit 21 is configured to acquire the broach geometric parameters, the broaching process parameters, and the workpiece material physical properties, wherein the broach geometric parameters include the rake angle γ0, the blade corner radius r e , the tooth rise t1, the tooth width w, and the cutting area S; the broaching process parameters include the broaching speed V, the inclination angle θ S of the wheel disc mortise and tenon, and the coolant temperature T C ; and the workpiece material physical properties include the density ρ, the specific heat capacity Cp, the thermal conductivity K, the melting point T m , the tool-chip friction coefficient μ, the yield stress A, the hardening constant B, the strain rate constant C, the hardening index n, the thermal softening index m, the initial yield stress σ0, the steady-state yield stress σ s , the reference strain rate , the strain coefficient r, and the strain rate coefficient D.

[0095] A cutting force calculation unit 22 is configured to calculate the shear flow stress on the main shear surface in the cutting process based on the broach geometric parameters, the process parameters, and the workpiece material physical properties, and further calculate the cutting force considering the strain softening and the temperature-strain rate coupling effect.

[0096] An extrusion force calculation unit 23 is configured to calculate the blade edge extrusion force caused by the broach blade edge corner radius based on the broach geometric parameters and the shear flow stress.

[0097] A wheel disc mortise and tenon broaching force calculation unit 24 is configured to superimpose the broaching force and the blade edge extrusion force to obtain the wheel disc mortise and tenon broaching force.

[0098] The wheel disc mortise broaching force regulating unit 25 is used for adjusting and controlling the broaching tool geometric parameters and the broaching process parameters according to the wheel disc mortise broaching force, and then optimizing the wheel disc mortise broaching force to meet the actual machining requirements.

[0099] In a specific implementation, the system can further include a data storage unit for storing the wheel disc mortise broaching tool structure parameters, the workpiece material parameters, the broaching process parameters and the wheel disc mortise broaching force calculation results.

[0100] As to the system in the above embodiments, the specific manner in which the various modules perform operations has been described in detail in the embodiments of the method, and will not be elaborated here.

[0101] For the system embodiments, since they basically correspond to the method embodiments, the relevant parts are referred to the part of the method embodiments. The system embodiments described above are merely illustrative, wherein the units described as separate components can or can not be physically separated, and the components displayed as units can or can not be physical units, i.e. they can be located in one place or distributed on multiple network units. Some or all of the modules can be selected to achieve the purpose of the present application according to actual needs. Those skilled in the art can understand and implement it without creative labor.

[0102] Correspondingly, the present application also provides a computer program product, comprising computer programs / instructions, which are executed by a processor to realize the wheel disc mortise broaching force regulating method as described above.

[0103] Correspondingly, the present application also provides an electronic device, comprising: one or more processors; a memory for storing one or more programs; when the one or more programs are executed by the one or more processors, the one or more processors realize the wheel disc mortise broaching force regulating method as described above. As Figure 4 As shown in the figure, a hardware structure diagram of the wheel disc mortise broaching force regulating system provided by the embodiment of the present application is in any device with data processing capability, in addition to Figure 4 In addition to the processor, the memory and the network interface shown in the figure, any device with data processing capability in which the device in the embodiment is usually according to the actual function of the any device with data processing capability, can also include other hardware, and will not be elaborated here.

[0104] Correspondingly, the application further provides a computer readable storage medium, which stores computer instructions, and the instructions are executed by a processor to implement the wheel disc mortise broaching force regulation method. The computer readable storage medium can be an internal storage unit of any device with data processing capability, such as a hard disk or a memory. The computer readable storage medium can also be an external storage device, such as a plug-in hard disk, a smart media card (SMC), an SD card, a flash card, etc. Further, the computer readable storage medium can include both the internal storage unit of any device with data processing capability and the external storage device. The computer readable storage medium is used to store the computer program and other programs and data required by the device with data processing capability, and can also be used to temporarily store data that has been output or will be output.

[0105] Other embodiments of the application will be apparent to those skilled in the art from consideration of the specification and practice of the application disclosed herein. It is intended that the application embrace any and all variations of the application that fall within the scope of the general inventive concept as defined in the claims and that the application include all modifications, equivalents and alternatives falling within the scope of the application.

Claims

1. A method for adjusting the broaching force of a wheel mortise and tenon joint, characterized in that, include: (1) Obtain the broach geometry parameters, broaching process parameters, and workpiece material physical properties, wherein the broach geometry parameters include the rake angle γ0 and the cutting edge radius r. e Tooth rise t1, tooth width w, cutting area S; broaching process parameters include broaching speed V, and the inclination angle θ of the wheel groove. S Coolant temperature T C The physical properties of the workpiece material include: density ρ, specific heat capacity Cp, thermal conductivity K, and melting point T. m The parameters are: coefficient of friction μ, yield stress A, hardening constant B, strain rate constant C, hardening exponent n, thermal softening exponent m, initial yield stress σ0, and steady-state yield stress σ. s Reference strain rate Strain coefficient r, strain rate coefficient D; (2) Based on the broach geometry parameters, broaching process parameters and physical properties of workpiece material, calculate the shear flow stress on the main shear surface during the cutting process, and further calculate the cutting force considering strain softening and temperature-strain rate coupling effect. (3) Based on the broach geometry parameters and shear flow stress, calculate the cutting edge extrusion force caused by the broach cutting edge radius; (4) The drawing force and the cutting edge extrusion force are superimposed to obtain the wheel mortise drawing force; (5) Based on the broaching force of the wheel groove, the geometric parameters of the broach and the broaching process parameters are adjusted and controlled to optimize the broaching force of the wheel groove to meet the actual processing requirements.

2. The method according to claim 1, characterized in that, Step (2) includes: (2.1) Calculate the friction angle β and the initial shear angle using the chip friction coefficient μ and the broach angle γ0. The final shear angle is obtained by optimizing based on the initial shear angle. (2.2) Based on the broach rake angle γ0, broach tooth rise t1, broaching speed V, and shear angle Calculate shear strain γ and shear strain rate (2.3) Based on broach tooth rise t1, broaching speed V, density ρ, specific heat capacity Cp, thermal conductivity K, melting point T m A. Yield stress; B. Hardening constant; C. Strain rate constant; D. Hardening index n; D. Thermal softening index m; E. Initial yield stress σ0; E. Steady-state yield stress σ s Reference strain rate Strain coefficient r, strain rate coefficient D, coolant temperature T C and shear strain γ and shear strain rate Given an initial shear force F s0 Under the premise of gradually correcting the shear stress τ s The final shear flow stress τ is obtained. s ; (2.4) Based on the broach rake angle γ0, broach tooth rise t1, broach tooth width w, and the inclination angle θ of the wheel mortise. S And friction angle β, shear angle Shear flow stress τ s Calculate the components F of the cutting force in the broaching direction, feed direction, and perpendicular to the broaching plane, considering strain softening and temperature-strain rate coupling effects. c F t and F P .

3. The method according to claim 2, characterized in that, Step (2.1) includes: Using the chip friction coefficient μ and the broach rake angle γ0, the friction angle β and the initial shear angle are calculated using equations (1) and (2). β=arctanμ (1) By combining formulas (3), (4), and (5) and solving iteratively, the final shear angle can be obtained. Where C n θ is the strain hardening exponent, and θ is an intermediate variable.

4. The method according to claim 2, characterized in that, In step (2.2), the shear strain γ and shear strain rate are calculated using formulas (6) and (7). Where q is the coefficient describing the non-uniform distribution of tangential velocity in the first deformation zone. This is the shear angle.

5. The method according to claim 2, characterized in that, In step (2.3), the shear strain γ and shear strain rate calculated in step (2.2) are... Given an initial shear force F s0 Under the premise of this, the shear stress τ is gradually corrected using equations (8) to (9). s When τ si -τ si-1 When the stress is less than a predetermined threshold, the final shear flow stress τ is determined. s : Where η is the proportionality coefficient for the conversion of shear energy into enthalpy, and ξ is the heat distribution coefficient.

6. The method according to claim 2, characterized in that, In step (2.4), the broach rake angle γ0, broach tooth rise t1, broach tooth width w, and the inclination angle θ of the wheel mortise are used. S And the friction angle β and shear angle calculated in step (2.1) The shear flow stress τ obtained in step (2.3) s The cutting force component F is calculated using formula (11). c F t and F P :

7. The method according to claim 1, characterized in that, In step (3), the components P of the cutting edge extrusion force in the broaching direction, feed direction, and perpendicular to the broaching plane are calculated using formula (12). c P t With P P : Where ψ is the angle between the material separation point on the cutting edge and the vertical direction, and τ s This refers to shear flow stress.

8. The method according to claim 1, characterized in that, In step (4), the components of the broaching force and the cutting edge extrusion force in the broaching direction, the feed direction, and perpendicular to the broaching plane are superimposed using formula (13) to obtain the corresponding component of the wheel mortise broaching force F. Then, the wheel mortise broaching force F is obtained according to formula (14): Among them, F c F t and F P P represents the components of the cutting force in the broaching direction, feed direction, and perpendicular to the broaching plane. c P t With P P It is the component of the cutting edge extrusion force in the broaching direction, the feed direction, and perpendicular to the broaching plane.

9. A wheel-type tenon-groove broaching force control system, characterized in that, include: The data acquisition unit is used to acquire broach geometry parameters, broaching process parameters, and workpiece material physical properties, wherein the broach geometry parameters include the rake angle γ0 and the cutting edge fillet radius r. e Tooth rise t1, tooth width w, cutting area S; broaching process parameters include broaching speed V, and the inclination angle θ of the wheel groove. S Coolant temperature T C The physical properties of the workpiece material include: density ρ, specific heat capacity Cp, thermal conductivity K, and melting point T. m The parameters are: coefficient of friction μ, yield stress A, hardening constant B, strain rate constant C, hardening exponent n, thermal softening exponent m, initial yield stress σ0, and steady-state yield stress σ. s Reference strain rate Strain coefficient r, strain rate coefficient D; The cutting force calculation unit is used to calculate the shear flow stress on the main shear plane during the cutting process based on the broach geometry parameters, process parameters and physical properties of the workpiece material, and further calculate the cutting force considering strain softening and temperature-strain rate coupling effects. The cutting edge extrusion force calculation unit is used to calculate the cutting edge extrusion force caused by the corner radius of the broach based on the broach's geometric parameters and shear flow stress. The wheel mortise and tenon broaching force calculation unit is used to superimpose the broaching force and the cutting edge extrusion force to obtain the wheel mortise and tenon broaching force; The broaching force control unit is used to adjust and control the broaching geometry and broaching process parameters based on the broaching force of the wheel groove, thereby optimizing the broaching force of the wheel groove to meet actual processing requirements.

10. The system according to claim 9, characterized in that, Also includes: The data storage unit is used to store the structural parameters of the wheel mortise and tenon broach, the workpiece material parameters, the broaching process parameters, and the calculation results of the wheel mortise and tenon broaching force.

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