Development of advanced broaching tool for machining titanium alloy

Broaching is a precision multipoint metal removal operation normally employed for manufacturing variety of complex parts having either internal or external features. Broaching can produce high precision and good surface finish at a high metal removal rate. The unique feature of a broach tool is that the feed/depth of cut for the teeth is built into the broach unlike other cutting tools. The tool design (e.g., rise per tooth and tooth geometry) play a vital role in the broach performance. A specially adapted machine tool modified to investigate a single broach tooth has been used. Cutting forces and material removal rate have been measured during experimental work for different combination of broaching parameters and broach tool geometry. The effect of the parameters on the surface quality produced has been established. The characteristics of chips formed have also been defined. Finally, optimum tooth geometry and rise per tooth have been recommended for tool performance, broached surface quality and efficient chip formation. The information provided in this paper will be beneficial for broach tool designers and manufacturing engineers.