PREDICTION OF CUTTING FORCES IN BROACHING OPERATION

Prediction of cutting forces is one of the fundamental stages in the modeling of machining processes. The costly machining tests can be replaced by virtual simulations where cutting parameters and material properties can be altered repeatedly with no cost. Broaching is one of the machining operations which is extensively used in the industry. The geometry of broaching tool varies according to the desired profile of the workpiece which can be a simple line or complicated curves. This broad range of geometries imposes complexity on the distribution of the chip load along the cutting edge. Therefore, introducing a practical force model for broaching operation can be challenging. An attempt is made in this paper to present a force model for broaching. The newly proposed force model expresses the cutting edge as a B-spline parametric curve and uses its flexibility to calculate the chip load as well as cutting forces for orthogonal and oblique broaching. Verified by previously published experimental results, the presented model has a great capability to simulate broaching cutter geometry along with cutting forces.