Effect of Tool-Work Deflections on the Shape of a Broached Hole

Abstract

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.

Surface Integrity of Broached Inconel 718 and Influence of Thermal Exposure

“…F. Klocke et al studied the broaching of Inconel 718 with cemented carbide, and compared its performance with that produced by traditional high speed steels in terms of tool wear, cutting forces and surface integrity [33]. Some other issues of broaching were also reported in relation to tool condition monitoring [34], coolant effect on surface finish [35], dynamics of broaching [36] and accuracy [37].…”

An example of selection of the cutting conditions in broaching of heat-resistant alloys based on cutting forces, surface roughness and tool wear

“…The influences of the deflections of the workpiece/tool fixturing systems due to cutting force variations, on the geometrical accuracy of the workpiece both for external [4] and internal broaching [5] were reported. The quality issues related to the formation of staggered semi-circular grooves, due to lateral tool vibration, were investigated in internal broaching [6].…”

“…Some surface quality issues for broached components have been investigated [4][5][6][7][8]. The influences of the deflections of the workpiece/tool fixturing systems due to cutting force variations, on the geometrical accuracy of the workpiece both for external [4] and internal broaching [5] were reported.…”

Prediction of Cutting Forces in Broaching Operation

“…Their model showed the relationship between contact area, chip load, and cutting force. Sajeev et al 6,7 investigated the effects of broaching parameters on the tool and workpiece deflections and the final shape of the broached geometry. Budak 8 examined the performance of broaching tools used for broaching of waspaloy turbine discs with fir-tree profile based on the monitoring of force and power.…”