Geometrical optimization of the broaching tools by leveling of the cutting forces

Official URL: http://risc01.sabanciuniv.edu/record=b1817217 (Table of Contents)

Subtractive machining has been one of the most extensively used manufacturing methods since the industrial revolution and the broaching operation is one of the ideal and oldest machining processes for accomplishing various applications such as turbine disc fir-tree slots, non-circular internal holes and keyways. Since the broaching operation accomplished by the linear cutting motion. Although broaching process is the only machining operation in order to machine complicated profiles without using a rotary motion, it is one of the least studied one in the literature. Due to nature of the broaching process, the broach tool design is the most important step during this operation since except cutting speed there is no any other flexibility. Therefore, modeling of the cutting process and predicting critical parameters before the design stage is crucial for optimum tool design. In previous studies, an optimized model without considering constant cutting forces for broaching tool design was presented. However, developing a method to generate an optimized broach tool design based on constant cutting forces can eliminate potential problems (i.e. reduced tool life and chipping, tooth breakage, poor surface quality etc.) while decreasing its length. In this study, a method is developed in order to minimize the length of the broach, increase tool life and quality of the final part leading to reduction of whole process cost by leveling of the cutting forces in each broaching process cycle, i.e. roughing, semi-finishing and finishing.