The finite element analysis gives the stresses and deflections of the broach and workpiece while cutting and burnishing. This has been achieved by developing a suitable finite element program for solving linear and non-linear material behaviour problems. The broach has been considered to behave elastically. In case of burnishing, the stresses on the workpiece result in yielding, and hence, non-linear material behaviour is considered for the workpiece. The program has been further modified to compute residual stresses on the broached component. The movement of a single burnishing tooth through the workpiece is simulated in a step-by-step manner, leading to residual stresses on the broached surface. The burnishing tooth and corresponding portion of the workpiece are modelled using FEM. The effect of tool-work interference and the ratio of radial to axial force on the stresses and deflections while burnishing have been studied. The residual stresses left behind on the broached component have been analytically evaluated.
During the broaching process, the workpiece and the broach undergo deflections owing to the large forces involved. The final shape of the broached component is a consequence of the net effect of tool-work deflections during broaching. In this paper the final shape arrived at from the FEM analysis is compared with the actual shape after broaching. The shape produced by cutting teeth and burnishing teeth are separately discussed with the help of finite element analysis. The experimental and theoretical results have been analysed with a view to arriving at useful conclusions related to the broaching process and the broach design. Some relevant discussion is also included.
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