Modelling of macroscopic cutting forces in internal broaching of an X12Cr13 stainless steel

Abstract

Broaching operations require stiff machine tools that have to withstand high cutting forces. This work aims to develop a methodology to predict the macroscopic cutting forces on a real, internal broaching operation comprising a large number of teeth. The macroscopic forces are estimated, based on the addition of local forces that are applied to each section and are simultaneously in contact with the broach. These local forces are calculated using a model of specific cutting pressure, depending on the rise per tooth. This study uses two methods to identify this specific cutting pressure model, that is, a direct approach based on orthogonal cutting tests and an inverse approach based on an instrumented broaching operation. It is shown that the direct method is effective in identifying a specific cutting pressure model and enables the prediction of macroscopic forces. Moreover, the direct approach provides more comprehensive results in terms of radial forces.