Title: Parametric simulation of tool and workpiece interaction in broaching operation

Authors: Ali Hosseini; H.A. Kishawy

Addresses: Faculty of Engineering and Applied Science, Machining Research Laboratory, University of Ontario Institute of Technology, Oshawa, ON L1H 7K4, Canada ' Faculty of Engineering and Applied Science, Machining Research Laboratory, University of Ontario Institute of Technology, Oshawa, ON L1H 7K4, Canada

Abstract: The main objective of the presented paper is developing a new methodology for analytical simulation of broaching operation for the given profiles of workpiece. By utilising B-spline parametric functions, the generalised parametric approach which is developed in this paper is able to represent a broaching tool cutting edge with any arbitrary profile. The instantaneous tool-workpiece engagement is then automatically extracted for the provided broaching tool geometry using analytical parametric curve intersection approach. The chip area can be used directly to predict the cutting forces in orthogonal broaching or it can be segmented into elements to predict the cutting forces in oblique broaching. The results of the proposed method have been validated by series of experiments. These results have also been verified against the results of previously published works. The good agreement between the predicted engagement parameters and those which obtained from the experimental measurements confirms the validity of the proposed methodology. [Received 18 December 2012; Revised 30 May 2013; Accepted 13 July 2013]

Keywords: broaching; cutting force; B-spline interpolation; parametric curve intersection; parametric simulation; tool-workpiece interaction.

DOI: 10.1504/IJMR.2013.057750

International Journal of Manufacturing Research, 2013 Vol.8 No.4, pp.422 - 442

Published online: 29 Jan 2014 *

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