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Research Papers

On the Optimized Design of Broaching Tools

[+] Author and Article Information
A. Hosseini

e-mail: SayyedAli.Hosseini@uoit.ca

H. A. Kishawy

e-mail: Hossam.Kishawy@uoit.caMachining Research Laboratory,
Faculty of Engineering and Applied Science,
University of Ontario Institute of Technology (UOIT),
Oshawa, ON L1H 7K4, Canada

1Corresponding author.

Manuscript received April 9, 2013; final manuscript received August 29, 2013; published online November 5, 2013. Assoc. Editor: Xiaoping Qian.

J. Manuf. Sci. Eng 136(1), 011011 (Nov 05, 2013) (10 pages) Paper No: MANU-13-1153; doi: 10.1115/1.4025415 History: Received April 09, 2013; Revised August 29, 2013

Among the cutting tools that are utilized in industry broaching tools are the most expensive ones. Unlike other machining operations such as milling and turning in which a cutting tool can be used for producing a variety of shapes, the broaching tools are uniquely designed depending on the desired profile to be produced on the workpiece. Consequently, the shape of broaching tools may be altered from one case to the others. This shape can be a simple keyway or a complicated fir tree on a turbine disk. Hence, a proper design of the broaching tools has the highest priority in broaching operation. Every single feature of these expensive tools must be accurately designed to increase productivity, promote part quality and reduce manufacturing cost. A geometric model of the cutting tool and a predictive force model to estimate the cutting forces are two fundamental requirements in simulation of any machining operation. This paper presents a geometric model for the broaching tools and a predictive force model for broaching operations. The broaching tooth is modeled as a cantilevered beam and the cutting forces are predicted based on the energy spent in the cutting system. A design procedure has been also developed for identification of the optimized tool geometry aiming to achieve maximum metal removal rate (MRR) by considering several physical and geometrical constraints.

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Figures

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Fig. 1

Geometry of tools (a) End mill with helical cutting edges. (b) Indexable end mill with square insert. (c) Face mill with circular insert. (d) Turning tool with square insert [23]

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Fig. 2

Some workpiece profiles and corresponding broaching tool geometries [24]

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Fig. 3

General side profile of broaching tools

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Fig. 4

Design parameters of the side profile for sample broaching tool

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Fig. 5

Variation of thickness for a single tooth. (a) General geometry and coordinate system. (b) Tooth tip. (c) Tooth body. (d) Tooth root

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Fig. 7

Distribution of contact stress on the tooth rake face

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Fig. 8

Solving the teeth as a cantilever beam subjected to a distributed load

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Fig. 9

Stress–strain curves for (a) AISI 1045. (b) AISI 12L14. (c) Al 7075. (d) Brass

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Fig. 10

Experimental setup. (a) Geometry of the coupling. (b) Front and side profile of the broaching tool. (c) Test bed. (d) Geometry of the prepared sample. (e)–(g) Fixture and test configuration

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Fig. 11

Experimental validation. (a) AISI 12L14. (b) AISI 1045. (c) Al 7075. (d) Brass

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