Force-based Temperature Modeling for Surface Integrity Prediction in Broaching Nickel-based Alloys

Surface Integrity standards for safety-critical aero engine components are very high. Besides the properties of the work piece material, the selected process parameters for machining have a significant impact on the achieved part quality. The present article identifies thermal induced Surface Integrity parameters such as micro-hardness, white-etching-layers and increased residual tensile stress as most critical when broaching Nickel-based alloys and presents a force-based concept for temperature prediction. The achieved results with the new model approach are compared to in-process temperature measurements.