Development of an in-house cutting forces simulation for fir tree broaching process

Abstract

This article proposes a simulation of cutting forces in broaching of fir tree slots. Every step needed to build an in-house fir tree broaching simulation is presented. This simulation is based on the discretization of each tooth of the broach, computation of elementary cutting forces of each discretized section, and finally the summation of each elementary cutting force into a global axes system. This work also presents orthogonal cutting experiments to implement realistic specific cutting forces into the model. The simulation obtained is compared with the real force signals of a fir tree broach to evaluate the quality of the simulation. At the end, the application to industrial context is developed.