Broach tool design methodology and systems

A method for designing a broaching tool comprising the steps of:

• a) providing a geometry of a slot to be broached;
• b) providing a material dependent initial minimum tooth rise for a broach tool that includes multiple broach inserts;
• c) calculating a number of broach inserts and teeth per insert based upon steps a) and b);
• d) solid modeling the broach inserts from step c);
• e) calculating the stresses on the broach tool and deformation of the slot;
• f) determining whether the slot dimensions are within desired specifications based upon step e), including modeling cutting temperature at a cutting chip in the slot;
• g) revising the broach tool if the slot is outside the desired specifications, and performing steps c)-g) until the slot is within desired specifications;
• and
• h) manufacturing a broaching tool with design characteristics of the broach tool resulting from performing step a)-g).

A system for designing a broaching tool comprising:

• a processor configured to provide a geometry of a slot to be broached, to provide a material dependent initial minimum tooth rise for a broach tool that includes multiple broach inserts, to calculate a number of broach inserts and teeth per insert based upon the geometry and the material dependent initial tooth rise, to solid model the broach inserts from the calculated number of broach inserts and teeth per insert, to calculate the stresses on the broach tool and deformation of the slot, to determine whether the slot dimensions are within desired specifications based upon the calculated stresses and deformation;
• wherein the processor is configured to revise the broach tool if the slot is outside the desired specifications, and calculate a number of broach inserts and teeth per insert, solid model the broach inserts from the calculated number of broach inserts and teeth per insert, calculate the stresses on the broach tool and deformation of the slot, determine whether the slot dimensions are within desired specifications based upon the calculated stresses and deformation, and revise the broach tool if the slot is outside the desired specifications until the slot is within the desired specifications;
• and
• wherein the processor provides a check on the broach inserts by predicting at least one of a cutting temperature and a hydrostatic pressure at a cutting chip.