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<p>Developing an accurate external broaching force prediction model is helpful for identifying optimal tool design parameters with lower cost before machining slots on turbine discs. The existing prediction model is constructed based on Oxley’s parallel shear zone theory and neglects the cutting edge’s ploughing effect. By the existing model, the average relative error in cutting force and feed forces prediction is over 30% and 40%, respectively. This paper proposed a method for constructing an external broaching force prediction model based on the unequal division shear zone theory and took into account the cutting edge’s ploughing effect. Compared to the existing model, the relative errors in cutting force and feed force prediction are less than 19% and 7%, respectively. Moreover, an inverse identification method for Johnson-Cook (J-C) constitutive parameters under external broaching conditions was proposed. Once identified, these parameters can be applied to predict broaching forces for the same workpiece material with different cutting tools. Validation performed on AISI 1045 steel showed that the precision and applicability of broaching force predictions were much improved.</p>

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A method to develop an external broaching force prediction model and inversely identify Johnson-Cook material parameters

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Qingchuan HE,
  • Yongfu RUAN,
  • Weijun DOU,
  • Lvgao Lin,
  • Jun PAN

摘要

Developing an accurate external broaching force prediction model is helpful for identifying optimal tool design parameters with lower cost before machining slots on turbine discs. The existing prediction model is constructed based on Oxley’s parallel shear zone theory and neglects the cutting edge’s ploughing effect. By the existing model, the average relative error in cutting force and feed forces prediction is over 30% and 40%, respectively. This paper proposed a method for constructing an external broaching force prediction model based on the unequal division shear zone theory and took into account the cutting edge’s ploughing effect. Compared to the existing model, the relative errors in cutting force and feed force prediction are less than 19% and 7%, respectively. Moreover, an inverse identification method for Johnson-Cook (J-C) constitutive parameters under external broaching conditions was proposed. Once identified, these parameters can be applied to predict broaching forces for the same workpiece material with different cutting tools. Validation performed on AISI 1045 steel showed that the precision and applicability of broaching force predictions were much improved.