Optimization of broaching tool design

Broaching is a commonly used machining operation in manufacturing of variety of internal or external complex features. High quality surfaces can be generated with high productivity if proper conditions are used. The main disadvantage of broaching is that it is not possible to change any of the cutting parameters but the cutting speed during production. That is because all machining parameters, except cutting speed, are built into broaching tools which makes tool design the most important aspect of broaching. In this thesis, a procedure for the optimization of broaching tools is presented. First, the mechanics of the broaching process and general properties of the broach tools are explained. Important design parameters and the effects of them on the broaching process are demonstrated. Most broaching tools have several tool segments with different profiles. One of the critical factors in the design of these tools is the assignment of segment profiles which determine the relative amounts of material removal rate in each section. Several alternatives are tried for optimization of section geometries and their effects are demonstrated by simulations. The objective function of the optimization problem and the constraints due to machine, tool and part limitations are presented. A heuristic optimization algorithm is developed, and demonstrated by examples. It is also shown that by using the algorithm developed the production time can be reduced due to shortened tool length. The simulation program developed is also explained and demonstrated.

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