Modeling of broaching for optimization purposes

Official URL: http://risc01.sabanciuniv.edu/record=b1081773 (Table of Contents)

High productivity and high quality can be achieved in broaching if the process is applied properly. Roughing, semi-finishing and finishing can be performed in one stroke of the tool increasing productivity and reducing set-up time. Furthermore, high quality surface finish can be obtained due to straight motion of the tool. One big disadvantage of broaching is that all process parameters, except cutting speed, are built into broaching tools. Therefore, it is not possible to modify cutting conditions during the process once the tool is manufactured. Improved design of broaching tools needs detailed modeling and analysis of the broaching process. In this thesis, tool optimization method and process models are presented. Cutting forces, tooth stresses, part deflections are modeled and analyzed using cutting models and FEA. The results of the analysis are summarized in analytical forms so that they can be used for different cases although in this thesis turbine disc broaching is considered as the application which is one of the most complex broaching operations. The developed models are implemented into a simulation program and the force, power, tooth stress and part deflection predictions are presented. The broach tool design is improved. Applications of the model for improved tool design are demonstrated by examples.