Broach Tool Rake Face Tailored Topography
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Solution Overview
Problem
Broaching processes for aerospace materials face issues such as excessive material strain hardening, surface microstructure alteration, slot deformation due to high friction forces, and reduced dimension accuracy, primarily in the machining of fir-tree slots for gas turbine engine components.
Innovation Solution
A broach tool with a tailored surface topography, specifically designed to reduce friction through laser surface treatment, electro-discharge machining, or other surface texturing methods, which includes features like depressed wells and microchannels to control lubricant flow and friction, formed by various processing methods such as laser machining, EDM, or high-energy deposition techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional broaching processes are used on aerospace materials, then material removal is achieved, but excessive material strain hardening occurs and surface microstructure is altered
Solution Approach 1:
The patent applies laser surface treatment to modify the surface topography parameters of the broach tool rake face, creating tailored micro-geometries that control friction and lubricant flow. This parameter change in surface characteristics reduces friction forces during broaching, thereby preventing excessive strain hardening and microstructure alteration while maintaining material removal productivity
Solution Approach 2:
The patent replaces conventional mechanical surface preparation methods with laser-based energy field processing. Laser surface treatment creates the desired surface topography without mechanical contact, avoiding the strain hardening and microstructure alteration that would result from mechanical machining of the tool surface itself
2Productivity
If conventional broaching is used, then slots are machined, but high friction forces cause slot deformation and reduced dimension accuracy
Solution Approach 1:
By changing the surface topography parameters of the rake face through laser treatment, the patent creates micro-geometries that reduce friction coefficients during the broaching operation. This friction reduction prevents slot deformation and maintains dimension accuracy while preserving slot machining productivity
Solution Approach 2:
The tailored surface topography acts as an intermediary between the broach tool and the workpiece material. The micro-geometries on the rake face interface control the interaction mechanics, reducing friction forces and preventing direct high-stress contact that causes slot deformation
3Productivity
If conventional broach tools are used, then cutting action is performed, but tool life is reduced due to high friction and wear
Solution Approach 1:
The patent modifies the surface parameters of the rake face through laser surface treatment, creating a tailored topography that reduces friction during cutting. This friction reduction decreases wear rates on the tool surface, extending broach tool life while maintaining effective cutting action
Solution Approach 2:
The laser surface treatment is applied to the broach tool rake face before the broaching operation begins. This preliminary modification of the surface topography prepares the tool to operate with reduced friction from the start, preventing premature wear and extending tool life throughout the cutting process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tailored surface topography reduces friction forces by approximately one-third, leading to reduced slot deflection and stress, extending broach tool life and improving dimension accuracy while lowering production costs.
Implementation Method 1
A broach tool according to one disclosed non-limiting embodiment of the present disclosure includes a broach tool rake face with a tailored surface topography. A further embodiment of the present disclosure includes, wherein the tailored surface topography is a laser surface treatment.
Implementation Method 2
A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the tailored surface topography is laser hardened.
Implementation Method 3
A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the tailored surface topography is Electro-Discharge Machined.
Data Source
AI summary
A broach tool includes a broach tool rake face with a tailored surface topography.