Force Prediction Methodology for Complex Shape Broaching

Abstract

Broaching is widely used for the manufacturing of complex geometries which requires high dimensional accuracy and surface finishing (e.g., fir tree, dovetail). A software development for force prediction in complex shape broaching is presented. The software automatically extracts the local uncut chip section along each tooth of the tool and based on the empirical specific cutting forces of the material the total force per tooth is calculated. The software was validated experimentally. For that purpose, fir trees of Inconel 718 were broached. Predicted forces showed an average relative error of 6% when compared to the experimental results.