Simulation of broaching operations for tool design optimization

In this study, an approach for simulation of broaching operations is presented. The proposed approach calculates the cutting forces, power, maximum stress at the tooth root, chip thickness and rake angle distribution on all teeth, and the workpiece geometry evolution during the process. The developed algorithms are integrated in a computer software that can simulate a whole broaching process to predict various physical parameters and generate some performance measures. The model which is used to optimize the broaching process is briefly presented here together with the industrial applications.