The Experts below are selected from a list of 2796 Experts worldwide ranked by ideXlab platform
Dragos Axinte - One of the best experts on this subject based on the ideXlab platform.
-
an experimental analysis of damped coupled vibrations in Broaching
International Journal of Machine Tools & Manufacture, 2007Co-Authors: Dragos AxinteAbstract:The paper reports for the first time aspects related to dynamics of Broaching when features with complex geometries are generated. It describes an experimental analysis of causes and outcomes of damped-coupled vibrations when Broaching semi-closed profiles, i.e. dovetails of gas turbine engines disks. Singular indentations or groups of tilted chatter marks were found in particular zones on broached surfaces. Analysis of force and acceleration signals revealed that damped-coupled vibrations that result in tilted chatter marks mainly occur due to specific geometry of cutting edges that enable coupling of three-dimensional (3D) vibrations. A new method to detect the appearance of tilted marks as a result of damped-coupled vibrations with particular frequency has been proposed by monitoring the elliptical movement of cutting edge via time and frequency domain analysis of two acceleration signals.
-
development of an online machining process monitoring system a case study of the Broaching process
The International Journal of Advanced Manufacturing Technology, 2007Co-Authors: Dragos Axinte, Dongfeng Shi, Nabil GindyAbstract:This paper presents a new online machining process monitoring system based on the PXI hardware platform and the LabVIEW software platform. The whole system is composed of the following interconnected packages: sensing, triggering, data acquisition, characterisation, condition monitoring and feature extraction packages. Several signal processing methods, namely, cross-correlation, resample, short-time Fourier transform (STFT) and statistical process control, are developed to extract the features of tool malfunctions and construct the thresholds of malfunction-free zones. Experimental results show that the developed online process monitoring system is efficient for acquiring, analysing and presenting sensory signals simultaneously, while the developed signal processing techniques are effective for detecting tool wear and constructing thresholds for tool-malfunction-free zones. Additionally, a sensitivity analysis of the signals acquired from alternative sensors versus those collected from a dedicated platform dynamometer has been carried out. This enables the evaluation of the possibility to employ alternative sensing techniques in an industrial environment.
-
approach into the use of probabilistic neural networks for automated classification of tool malfunctions in Broaching
International Journal of Machine Tools & Manufacture, 2006Co-Authors: Dragos AxinteAbstract:The condition of Broaching tools has crucial importance for the surface quality of the machined components. If undetected, tool malfunctions such as wear, chipping and breakage of cutting teeth can result in severe damage or even scrapping expensive components, with direct implications on increasing the overall manufacturing costs. In contrast with other machining operations, Broaching is characterised by non-symmetric distributions of cutting forces vs. time, making more difficult the task of recognising tool malfunctions. The paper reports on a methodology to automatically detect and classify tool malfunctions in Broaching. The method was demonstrated through the use of time domain distribution of the push-off cutting force as a key sensory signal to monitor Broaching tool condition when machining a nickel-based aerospace alloy. The characteristic features of the sensory signals have been extracted using in-house-developed programs and, afterwards, used to train and test a probabilistic neural network that enables automated classification of tools with fresh, worn, chipped and broken teeth. Inputting new pattern characteristics to the main categories of tool malfunctions, the system successfully classified them even when variations of signal amplitude and ranking of malfunctioned teeth occurred.
-
an example of selection of the cutting conditions in Broaching of heat resistant alloys based on cutting forces surface roughness and tool wear
Journal of Materials Processing Technology, 2005Co-Authors: Dragos Axinte, T H Hyde, Nabil GindyAbstract:Abstract Despite the fact that Broaching has been used for long a time as a machining process for manufacturing highly accurate, complex profiles, little work has been published on the selection of cutting conditions to maximise tool life while achieving the required surface quality and level of cutting forces. This is even more important when notorious difficult-to-cut materials, such as Ni and Ti alloys, used in the aero-engine/power generation industry where high geometrical accuracy, along with restricted surface quality are required. The paper describes a multi-step methodology to select the cutting conditions for the Broaching of Ni and Ti alloys used in the manufacture of aero-engines and power generators. Based on the application of the Taguchi technique, the cutting conditions (cutting speed, rise per tooth, rake angle, coolant type) were selected in order to obtain fine surface quality along with reasonably low levels of main cutting force (Fz) and perpendicular cutting force (Fy). This was followed by a reduced number of tool life tests which were carried out in order to select the final cutting conditions. Scanning electron microscopy (SEM) and chemical composition analysis on the flank and rake faces of the tools were employed to characterise the worn tools. It was found that when Broaching forces, surface roughness and tool life are considered as process output measures, and taking into consideration generic process constraints on process productivity, machine tool stability, and tool stiffness, only a “pseudo-optimal” solution for the cutting conditions could be specified.
-
Broaching of ti 6 4 detection of workpiece surface anomalies on dovetail slots through process monitoring
CIRP Annals, 2005Co-Authors: Dragos Axinte, Nabil Gindy, F Oud, J Penny, David J WilliamsAbstract:Surface anomalies induced by abusive Broaching represent a concern for the safety of critical components of aero-engines. Using acoustic emission and force signals, the paper reports on process monitoring techniques to detect surface anomalies when abusively Broaching dovetail slots in Ti-6-4. Parallel surface inspection helped in defining the correlation between the occurrence of uneven events in the output signals and the appearance/location of anomalies on the broached surfaces. The findings support the definition of process monitoring strategies to detect workpiece surface anomalies including surface deformation/ overheating, directed scoring and smearing of parent material.
Nabil Gindy - One of the best experts on this subject based on the ideXlab platform.
-
development of an online machining process monitoring system a case study of the Broaching process
The International Journal of Advanced Manufacturing Technology, 2007Co-Authors: Dragos Axinte, Dongfeng Shi, Nabil GindyAbstract:This paper presents a new online machining process monitoring system based on the PXI hardware platform and the LabVIEW software platform. The whole system is composed of the following interconnected packages: sensing, triggering, data acquisition, characterisation, condition monitoring and feature extraction packages. Several signal processing methods, namely, cross-correlation, resample, short-time Fourier transform (STFT) and statistical process control, are developed to extract the features of tool malfunctions and construct the thresholds of malfunction-free zones. Experimental results show that the developed online process monitoring system is efficient for acquiring, analysing and presenting sensory signals simultaneously, while the developed signal processing techniques are effective for detecting tool wear and constructing thresholds for tool-malfunction-free zones. Additionally, a sensitivity analysis of the signals acquired from alternative sensors versus those collected from a dedicated platform dynamometer has been carried out. This enables the evaluation of the possibility to employ alternative sensing techniques in an industrial environment.
-
an example of selection of the cutting conditions in Broaching of heat resistant alloys based on cutting forces surface roughness and tool wear
Journal of Materials Processing Technology, 2005Co-Authors: Dragos Axinte, T H Hyde, Nabil GindyAbstract:Abstract Despite the fact that Broaching has been used for long a time as a machining process for manufacturing highly accurate, complex profiles, little work has been published on the selection of cutting conditions to maximise tool life while achieving the required surface quality and level of cutting forces. This is even more important when notorious difficult-to-cut materials, such as Ni and Ti alloys, used in the aero-engine/power generation industry where high geometrical accuracy, along with restricted surface quality are required. The paper describes a multi-step methodology to select the cutting conditions for the Broaching of Ni and Ti alloys used in the manufacture of aero-engines and power generators. Based on the application of the Taguchi technique, the cutting conditions (cutting speed, rise per tooth, rake angle, coolant type) were selected in order to obtain fine surface quality along with reasonably low levels of main cutting force (Fz) and perpendicular cutting force (Fy). This was followed by a reduced number of tool life tests which were carried out in order to select the final cutting conditions. Scanning electron microscopy (SEM) and chemical composition analysis on the flank and rake faces of the tools were employed to characterise the worn tools. It was found that when Broaching forces, surface roughness and tool life are considered as process output measures, and taking into consideration generic process constraints on process productivity, machine tool stability, and tool stiffness, only a “pseudo-optimal” solution for the cutting conditions could be specified.
-
Broaching of ti 6 4 detection of workpiece surface anomalies on dovetail slots through process monitoring
CIRP Annals, 2005Co-Authors: Dragos Axinte, Nabil Gindy, F Oud, J Penny, David J WilliamsAbstract:Surface anomalies induced by abusive Broaching represent a concern for the safety of critical components of aero-engines. Using acoustic emission and force signals, the paper reports on process monitoring techniques to detect surface anomalies when abusively Broaching dovetail slots in Ti-6-4. Parallel surface inspection helped in defining the correlation between the occurrence of uneven events in the output signals and the appearance/location of anomalies on the broached surfaces. The findings support the definition of process monitoring strategies to detect workpiece surface anomalies including surface deformation/ overheating, directed scoring and smearing of parent material.
-
tool condition monitoring in Broaching
Wear, 2003Co-Authors: Dragos Axinte, Nabil GindyAbstract:Abstract The paper reports on research which attempts to correlate the condition of Broaching tools to the output signals obtained from multiple sensors, namely, acoustic emission (AE), vibration, cutting forces and hydraulic pressure, connected to a hydraulic Broaching machine. Broaching tools in a variety of conditions, namely, freshly ground teeth, one or more chipped teeth, one or more weakened teeth, one or more broken teeth and tools showing uniform wear, were investigated. Single tooth and multiple teeth Broaching tools were employed during the Broaching trials and the sensory signals were analysed both in the time and frequency domains. The results show that AE, vibration and cutting force signals are all sensitive to tool condition and a correlation can be made between the Broaching tool condition and sensory signals using a variety of signal analysis techniques. A brief review of the advantages and the disadvantages of each sensor/signal and its associated analysis technique is presented. It is concluded that the most sensitive sensors to changes in tool condition are not necessarily those that are easy to mount or incorporate in a Broaching machine. This can impose restrictions on the types of sensors that can be retrofitted to current machines. The condition monitoring system is currently being extended to incorporate sensor fusion techniques to increase the flexibility of the monitoring system and improve confidence in decision-making.
Naoya Umeda - One of the best experts on this subject based on the ideXlab platform.
-
estimation of Broaching probability using wave induced forces and moments measured in captive model tests
Journal of Marine Science and Technology, 2019Co-Authors: Thet Zaw Hte, Naoya Umeda, Akihiko Matsuda, Atsuo Maki, Daisuke TeradaAbstract:Broaching is a stability failure that involves many force components. Wave-induced forces, in particular, play an important role in the estimation of Broaching, and it is necessary for these forces to be estimated accurately. Captive model experiments of wave forces in regular waves were, therefore, conducted for tumblehome and flare vessels (the vessels were based on ones developed by the US Office of Naval Research). Empirical correction factors of the wave forces for different wavelength-to-ship length ratios and heading angles were obtained; the difference between theoretical calculations and experimental values obtained in the present were used to develop these factors. These empirical correction factors were then added into a theoretical study and the results from this study were compared with that of a free-running model experiment not only in regular waves but also in irregular waves for both the tumblehome and flare vessels. The results indicate that if the empirical corrections of the wave forces depending on the wavelength are used, then the Broaching probability in irregular waves can be well estimated for these two types of vessels.
-
Broaching probability for a ship in irregular stern-quartering waves: theoretical prediction and experimental validation
Journal of Marine Science and Technology, 2016Co-Authors: Naoya Umeda, Satoshi Usada, Kentaro Mizumoto, Akihiko MatsudaAbstract:To avoid stability failure due to the Broaching associated with surf riding, the International Maritime Organization (IMO) has begun to develop multilayered intact stability criteria. A theoretical model using deterministic ship dynamics and stochastic wave theory is a candidate for the highest layer of this scheme. To complete the project, experimental validation of the theoretical method for estimating Broaching probability in irregular waves is indispensable. We therefore conducted free-running model experiments using a typical twin-propeller and twin-rudder ship in irregular waves. A simulation model of coupled surge–sway–yaw–roll motion was simultaneously refined. The Broaching probability calculated by the theoretical method was within the 95 % confidence interval of that obtained from the experimental data. This could be an example of experimental validation of the theoretical method for estimating the Broaching probability when a ship meets a wave.
-
Broaching prediction of a wave-piercing tumblehome vessel with twin screws and twin rudders
Journal of Marine Science and Technology, 2011Co-Authors: Hirotada Hashimoto, Naoya Umeda, Akihiko MatsudaAbstract:The new intact stability criteria which are under development at the International Maritime Organization (IMO) are required to cover a Broaching phenomenon, well known as a great threat to high-speed vessels which can lead to capsizing. Some reports exist which demonstrate that their numerical models can predict a highly nonlinear phenomenon of Broaching. However, additional validation studies are needed for unconventional vessels, in addition to conventional ones, to develop direct stability assessment methods for the new intact stability criteria. In this research, we selected as the subject ship a wave-piercing tumblehome vessel with twin screws and twin rudders, a design expected to be one of a new generation of high-speed monohull ships. Firstly, a series of captive model tests were conducted to measure the resistance, the manoeuvring forces, the wave-exciting forces, the heel-induced hydrodynamic forces, and the roll restoring variation for the unconventional tumblehome vessel. Secondly, the existing mathematical model which had been developed for Broaching prediction of conventional vessels with a single propeller and a single rudder was extended to unconventional vessels with twin propellers and twin rudders. Finally, comparisons between numerical simulations and the existing free running model experiments were conducted. As a result, it was demonstrated that fair quantitative prediction of Broaching is realised when the rudder force variation, the roll restoring variation and the heel-induced hydrodynamic force for large heel angles are taken into account.
-
an improvement of Broaching prediction with a nonlinear 6 degrees of freedom model
日本船舶海洋工学会論文集 = Journal of the Japan Society of Naval Architects and Ocean Engineers, 2011Co-Authors: Motoki Araki, Hirotada Hashimoto, Naoya Umeda, Akihiko MatsudaAbstract:This paper reports on the improvements of a simulation model for ship motions in following and quartering waves. The authors use a wave-piercing tumblehome vessel as a subject ship. The existing 4-DoF (degrees of freedom) model shows some limitation in its capability for predicting Broaching of this vessel. In a free-running model experiment for the vessel, we observed rudder and propeller emersion from the water leading to Broaching. This rudder and propeller emersions can significantly reduce steering performance. To express these rudder and propeller emersions, we should take account of not only roll but also pitch and heave.Therefore the authors develop a 6-DoF model. With the heave and pitch motion, we can calculate the local draft variation for calculating wave exiting forces and moments. Roll restoring variations are one of the important factors to estimate roll motions.Therefore we theoretically estimate restoring variations in wave then we found the tendency of variation dramatically changes due to the roll angle. Submergence of superstructure can be important for that variation. We also consider the variation of maneuvering coefficients and rudder forces in waves which are relevant to Broaching. To estimate these variations, we conduct PMM tests, straight-line tests and rudder angle tests in waves using a scale model of subject ship. With some of these improvements, we obtain better agreements with experimental results than existing 4-DoF model.
-
cfd system based and efd study of ship dynamic instability events surf riding periodic motion and Broaching
Ocean Engineering, 2011Co-Authors: Hamid Sadathosseini, Shinya Yamamura, Pablo M. Carrica, Frederick Stern, Hirotada Hashimoto, Naoya Umeda, Akihiko MastudaAbstract:CFD and system-based simulation are used to predict Broaching, surf-riding, and periodic motion for the ONR Tumblehome model, including captive and free model test validation studies. CFD shows close agreement with EFD for calm water resistance, static heel (except for sway force and yaw moment), and static drift (except for roll moment). CFD predictions of static heel in following waves also compare well with EFD except for surge force, sway force, and pitch angle. Froude–Krylov calculations of wave-induced surge force in following waves provides good agreement for high Froude number, but significantly overestimates for Froude number less than 0.2. On the other hand, CFD successfully reproduces the reduction of the wave-induced surge force near Froude number 0.2, probably because CFD can capture the 3D wave pattern. CFD free model simulations are performed for several speeds and headings and validated for the first time for surf-riding, Broaching, and periodic motions. System-based simulations are carried out based on inputs from EFD, CFD, and Froude–Krylov for a dense grid of speeds and headings to predict the instability map, which were found to produce fairly similar results.
Volke Schulze - One of the best experts on this subject based on the ideXlab platform.
-
hard Broaching of case hardened sae 5120
Procedia CIRP, 2014Co-Authors: H Meie, Kevi Ninomiya, David Dornfeld, Volke SchulzeAbstract:Abstract To achieve knowledge of the effects of Broaching to the component and the influence on subsequent process steps such as heat treatment and hard machining, Broaching experiments were performed on plates made of normalized case hardening steel SAE 5120 in [1] . To investigate the effect of heat treatment, five Broaching variants of [1] were chosen and hardened with two different case hardening depths, which were observed for effects generated from the surface layer carbon fraction. The hardened variants were analyzed for distortion generated through the hardening step and the specimen subsequently underwent a hard Broaching stage in dry machining conditions. The cutting forces were monitored in-process, and the residual stress of the machined surface was determined using X-ray diffraction after the experiment. Surface roughness measurements also complemented the results. The results indicated that the cutting forces depend on existing distortion and therefore the volume material removed. It can also be seen that there is little influence on cutting forces with rising cutting speeds. Compressive residual stresses were present after heat treatment, but turned into tensile residual stress states after hard Broaching. Effects from different case hardening depths and cutting speeds in the formation of surface roughness and residual stress could not be detected.
-
surface quality after Broaching with variable cutting thickness
Procedia CIRP, 2014Co-Authors: Frederik Zange, Nikolay Oev, Volke SchulzeAbstract:Abstract During machining, new surfaces are generated. Depending on the machining process, different qualities of surfaces are produced. After Broaching, a high surface quality is expected. However, the quality can be influenced by vibrations of the machine structure which leads to varying cutting thicknesses and thus to low surface qualities. The influence of variable cutting thicknesses during machining was investigated experimentally and by means of simulations. Dynamic changes in cutting thickness were considered as geometrical profiles on the uncut surfaces. Process forces were measured during the experiments and the roughness before and after Broaching with one tooth was evaluated. The residual stresses in the workpiece surfaces were simulated with an already validated model of orthogonal machining using a self-implemented re-meshing method.
-
numerical investigations on changes of the main shear plane while Broaching
Procedia CIRP, 2013Co-Authors: Volke Schulze, Frederik Zange, Nikolay OevAbstract:Abstract The quality of broached components can be influenced by different factors, such as am-bient temperatures, human factors or vibrations of the machine structure induced by process-machine-interactions. These vibrations are normally initiated by changing pro-cess forces, which are mainly caused by cutting thickness or rake angle variations. Broached components are produced within one motion of the broach along the surface of the work piece, where multiple teeth in a row are in contact. The variation of the cut- ting thickness results from a wavy profile on the surface generated by the previous cut-ting process or the previous tooth. When the cutting thickness changes during the process, the rake angle varies, too. In some further published works, the changing cutting thickness and the changing rake angle during Broaching were investigated by means of machining simulations with the result that the process forces are still adjusting after the cutting thickness and the rake angle have already reached a stable value. The adjustment of the shear plane on the new cutting conditions is mentioned as the main reason. This paper presents some deeper investigations on this effect. Therefore, 2D machining simulations for different cutting thicknesses and cutting velocities are performed. The investigations show tendencies for the still adjusting shear plane after changing the cutting thickness or the rake angle during the cutting process. Finally, the simulation results are validated with experimentally observed data.
-
high speed Broaching of case hardening steel sae 5120
Procedia CIRP, 2012Co-Authors: Volke Schulze, H Meie, Tobias Strauss, Jens GibmeieAbstract:Abstract To achieve knowledge of the effects of Broaching to the component and the influence to subsequent process steps, Broaching experiments have been carried out on case hardening steel SAE 5120 using different tools and cutting speeds up to 50 m/min with use of cooling lubricant and in dry machining. The process forces were analyzed and the resulting surface was examined using X-ray diffraction and roughness testers. High cutting speeds lead to low cutting forces but high residual stresses. An influence of the varied parameters and machining conditions to the surface quality was not detected.
-
simulation of metal cutting process with variable cutting thickness during Broaching
Procedia CIRP, 2012Co-Authors: Volke Schulze, Nikolay Oev, Frederik ZangeAbstract:Abstract With the advancements of different simulation approaches several metal cutting processes have been simulated, investigated and improved. However, very little work has been published in the field of metal cutting with variable cutting thicknesses by means of cutting simulations. This paper presents a 2D cutting simulation approach using the finite element method (FEM), which is applied in order to predict cutting forces, temperatures and chip shapes while Broaching. To investigate the influence of varying cutting thicknesses the Broaching process is simulated with different constant cutting thicknesses at the beginning (20, 35 μm and 50 μm).
Fritz Klocke - One of the best experts on this subject based on the ideXlab platform.
-
Multi-Criteria Assessment of Machining Processes for Turbine Disc Slotting
MDPI AG, 2018Co-Authors: Fritz Klocke, Thomas Ergs, Enjami Doebbele, Marvi Inde, Marti SeimaAbstract:Many different process chains are possible to manufacture profiled grooves in turbine discs. Broaching with high speed steel tools is still state of the art today but as a consequence of the rising demand for aero engines, the disc manufacturers are striving for alternative high performance processes to increase both flexibility and productivity in the manufacturing of these safety critical features. Broaching machines are oftentimes at a bottleneck in the production of rotating turbine discs. Several other machining processes have been discussed in the context of slotting, such as Broaching with carbide tools, milling, water jet machining, W-EDM and grinding. Within this paper a multi-criteria assessment approach is presented dealing with slotting processes. The assessment comprehends economical, ecological, flexibility and productivity criteria, and is based on data gathered with an aero engine OEM. The technological aspects such as tool life and productivities are based on real machining tests that have been carried out within the project HoFePro. The assessment is conducted for multiple profile shapes that represent different sizes and geometrical complexities of profiled grooves. The manufacturing processes within the assessment include Broaching with HSS and carbide, milling with ceramics and carbide (side and end) as well as profile milling with carbide tools. The underlying workpiece material is a nickel-based alloy
-
Automatic Broaching Tool Design by Technological and Geometrical Optimization
Procedia CIRP, 2015Co-Authors: P. Vogtel, Dieter Lung, Fritz Klocke, Sergio TerziAbstract:Abstract The paper presents an approach for automatic Broaching tool design for a user-defined complex-shaped slot. A systematic method was developed to generate a cutting strategy for the broach. A set of technological constraints such as maximum allowed cutting force per tooth or maximum allowed rise per tooth are considered. Thereby, an optimization based on the cutting forces is carried out. Aim of the automatic, technological and geometrical based Broaching tool design is to reduce the total length of the Broaching tool. Hence, manufacturing cost of the tool itself is reduced as well as manufacturing time of each slot and thereby, production costs of the slots are optimized.
-
force based temperature modeling for surface integrity prediction in Broaching nickel based alloys
Procedia CIRP, 2014Co-Authors: Fritz Klocke, Sascha Gierlings, Matthias Ockma, D VeselovacAbstract:Abstract Surface Integrity standards for safety-critical aero engine components are very high. Besides the properties of the work piece material, the selected process parameters for machining have a significant impact on the achieved part quality. The present article identifies thermal induced Surface Integrity parameters such as micro-hardness, white-etching-layers and increased residual tensile stress as most critical when Broaching Nickel-based alloys and presents a force-based concept for temperature prediction. The achieved results with the new model approach are compared to in-process temperature measurements.
-
Broaching of inconel 718 with cemented carbide
Production Engineering, 2013Co-Authors: Fritz Klocke, P. Vogtel, Sascha Gierlings, Diete Lung, Draze VeselovacAbstract:Broaching is the standard process for machining complex-shaped slots in turbine discs. More flexible processes such as milling, wire EDM machining and water-jet cutting are under investigation and show promising results. In order to further use existing resources and process knowledge, the Broaching process has to be improved towards higher material removal rates. Taking into account that the state-of-the-art Broaching process is working with high-speed-steel tools, the higher thermal resistant cemented carbide cutting materials offer the potential to significantly increase cutting speeds, which lead to increased process productivity. The following article presents a broad study on Broaching with cemented carbide tools. Different cutting edge geometries are discussed on the basis of process forces, chip formation and tool wear mechanisms. Furthermore, a detailed comparison to the standard process is drawn.
-
modelling of process forces in Broaching inconel 718
Procedia CIRP, 2013Co-Authors: P. Vogtel, Fritz Klocke, Hendrik Puls, S Uchkreme, Diete LungAbstract:Abstract Broaching is the standard machining process for fir-tree slots in turbine discs. Due to the fact that Inconel 718 turbine discs belong to the safety critical components of aero engines, there are high demands on dimensional accuracy and surface quality. The cutting parameters as well as tool, fixture and machine tool are critical factors to fulfill these high requirements. Within the next years the process has to be designed for the needs of new turbine disc geometries, disc materials and tool materials. Therefore, detailed knowledge about process forces is an essential prerequisite. Modern 2D FEM simulations enable calculations of the thermo- mechanical load collective in the chip-tool interface. A 2D chip formation model of the Broaching process has been designed to calculate cutting forces for process relevant parameters, as the rake angle, rise per tooth and cutting speed. Depending on these parameters a multivariate regression model has been de- veloped. The chip formation and the multivariate regression model have been validated on a test bench for fundamental cutting investigations, simultaneous process forces were measured and high speed films were recorded. This paper thoroughly discusses the results and evaluates the application potential.
