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When is it time to sharpen the broach? Or what kind of wear should be considered? One way to assess this is by examining the condition of the broach itself and the workpiece being machined. For example, if the surface roughness of the broached groove on a turbine wheel appears poor, or if the broach shows signs of wear or chipping, it may indicate that the broach needs honing. Another approach is forced dressing, which involves setting a specific number of grooves to be broached before regrinding. Even if the broach doesn’t show visible damage or the surface finish remains good, it’s still necessary to perform forced grinding.
This is because during the broaching process, the broach is subjected to various stresses—tensile, torsional, compressive, impact, and thermal loads. Over time, these forces can cause microstructural changes in the broach material, such as fatigue softening or excessive fatigue. These changes may not be visible on the surface but can significantly affect performance. A broach may appear only slightly worn, yet it could be nearing its fatigue limit. Once that threshold is exceeded, wear can escalate quickly, leading to serious damage like chipping or breakage.
For fine broaching of 3 wheel slots, or for roughing and semi-finishing of 6 wheel slots, it's essential to repair the flank of the broach based on practical experience. Determining the right amount of material to remove each time depends on the tolerance requirements of the groove and the current condition of the broach. After testing, the flank wear can be observed under a microscope, and the appropriate amount of broaching can be decided based on economic and technical factors.
When repairing the rake face of the broach, several precautions must be taken:
1. **Clean the rake face thoroughly**. After broaching, swarf or built-up edges may form on the rake face. These should be removed using an oil stone to prevent excessive grinding and potential chipping of the cutting edge, which could shorten the broach’s life.
2. **Choose the right abrasive**. The broach is typically made from powder metallurgy high-speed steel T71245 (W12Cr4V5Co5), so the abrasive must match its grinding characteristics. A CBN grinding wheel with ceramic bonding agent V240, particle size B91 (170/200) or B107 (140/170), and concentration of 100% is recommended for CNC broach grinders.
3. **Use a suitable CNC broach grinder**, such as the ArthurKlink model shown in Figure 4, and follow the correct grinding parameters. Improper settings can lead to overheating, local annealing, and even chipping of the cutting edge. Refer to the table below for recommended settings.
4. **Remove burrs and passivate the edge**. After grinding, the broach may have burrs that extend toward the flank. These should be cleaned with a copper plate and then smoothed with a V-belt to avoid affecting the final dimensions and surface quality. If left unattended, they can cause chipping or damage during use.
5. **Measure the broach dimensions**. The tooth height and width of the first and last teeth should be measured and recorded on the broach’s history card. This data helps track the broach’s condition and ensures consistency when it is used again.
Each broach should have a detailed maintenance record to support its use and repair. The card should include information such as the broach type, number of grindings, amount removed each time, grinding duration, post-grinding dimensions, and any feedback from the broaching process.
In conclusion, while some data may vary between manufacturers, continuous improvement and collaboration between suppliers and users are essential to optimize the design, usage, and maintenance of gas turbine wheel groove broaches.
**Related News**: *Design and Use of Gas Turbine Wheel Groove Broach*