The effect of tool rake angle and cutting speed on cutting force during broaching process by using Finite Element Modeling

Broaching is a specific method of removing metal by tools that have successively increasing cutting edges, the part is made through tool moving in a certain path. The cutting force is high as a result of high removal rate in the broaching process. The process may have too many surface errors since high displacement arose by this cutting force. For this reason, proper attention should be paid in the broaching tool design, geometry analysis and the process conditions. Considering the broach machining table and accessories, the dynamometer installation is complicated. Therefore, the finite element modeling can be used for evaluating the cutting force. In this study, the simulation of broaching process is done using Abaqus Software. After modeling the process, the effect of rake angle and cutting speed parameters on cutting forces are investigated.