Modeling and analysis of cutting force in vibration-assisted broaching (VAB).

This paper aims to present a predicted force model of vibration-assisted broaching (VAB). Based on the geometric features and kinetic characteristics of broach, the model focuses on three important points: (i) the cutting force of single tooth, (ii) the number of teeth in contact with the workpiece, and (iii) the influence of simple harmonic motion (SHM). Firstly, according to the empirical approach (EA) and the shear angle (SA) theory, two kinds of single-tooth model of broaching are built. Secondly, considering the length of cutting edge and the number of cutting tooth, two multi-tooth models based on the single-tooth models are presented. Then, with the influence of broach motion, the models of VAB force are finally established. Verification experiments are conducted for the developed force model and show that the calculated results of SA model are more agreeing well with the experimental values when vibration frequency increased. In addition, the VAB model is helpful in the application of vibration broaching. [ABSTRACT FROM AUTHOR]