Title: Identifying parameters of a broaching design using non-linear optimisation

Authors: Ertunga C. Ozelkan, Ozkan Ozturk, Erhan Budak

Addresses: Systems Engineering and Engineering Management, and Center for Lean Logistics and Engineered Systems, The University of North Carolina at Charlotte, Charlotte, NC 28223, USA. ' Department of Mechanical Engineering and Center for Precision Metrology, The University of North Carolina at Charlotte, Charlotte, NC 28223, USA. ' Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli, Tuzla, Istanbul, 34956 Turkey

Abstract: Broaching is one of the most recognised machining processes that can yield high productivity and high quality when applied properly. One big disadvantage of broaching is that all process parameters, except cutting speed, are built into the broaching tools. Therefore, it is not possible to modify the cutting conditions during the process once the tool is manufactured. Optimal design of broaching tools has a significant impact to increase the productivity and to obtain high quality products. In this paper, an optimisation model for broaching design is presented. The model results in a non-linear non-convex optimisation problem. Analysis of the model structure indicates that the model can be decomposed into smaller problems. The model is applied to a turbine disc broaching problem which is considered as one of the most complex broaching operations.

Keywords: machining optimisation; turbine disks; broaching tool design; nonlinear optimisation; modelling; optimal design.

DOI: 10.1504/IJMIC.2011.039702

International Journal of Modelling, Identification and Control, 2011 Vol.12 No.3, pp.244 - 252

Published online: 21 Mar 2015 *

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