Simulation of the hone broaching process with diamond tools

Hone broaching is a finishing process characterized by an oscillatory movement of the single layer diamond tool. The tool consists of a conical roughing and a cylindrical finishing part. The finishing part increases the surface quality and reduces the tolerances. To reach a deeper understanding of the process, a stochastic model of the cutting tool was developed. It allows the examination of the influence of different process and tool parameters by numeric simulation based on the investigation of chip formation. Therefore, the simulation reproduces the macroscopic effects of the hone broaching process based on the fundamental microscopic description of single grains and their cutting edges’ engagements. The model-based analysis showed several suggestions for the improvement and optimization of the hone broaching process, which have been experimentally verified in this work. With a modified oscillatory strategy, a considerable process time reduction can be achieved.