Asymmetrical cutting-edge design of broaching tool based on FEM simulation

Finite element method (FEM) based model of broaching Inconel 718 was established to optimize an asymmetrical cutting-edge by the commercial software AdvantEdge in this paper. The asymmetrical cutting-edge form by two circles was proposed. The power-law (P-L) material constitutive model, including strain hardening, strain rate hardening and thermal softening was developed by split Hopkinson pressure bar (SHPB) test and high temperature Vickers hardness test. The parameters of thermal properties were measured by laser flash diffusivity apparatus. The friction model between TiN (The outer layer coating material of the tool) and Inconel 718 was obtained by ball on disc friction test. The simulated and experimental results have been compared comprehensively in the items of chip formation and tool wear width. The results showed that the simulated results were consistent with the experimental results. The average errors of chip curl radius, chip thickness, wear width of rake face and flank face were 7.68%, 3.56%, 13.64% and 12.24%, respectively, which proved the accuracy of the simulation model. Then the optimal asymmetrical cutting-edge of broach were obtained through orthogonal test based on the accurate FEM model. The rise per tooth of the optimal broach tool is 0.04 mm/tooth, the rake angle is 13 & DEG;, the circle radius R1 is 0.13 mm, and the circle radius R2 is 0.02 mm.& COPY; 2023 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).