Simulation of Metal Cutting Process with Variable Cutting Thickness During Broaching

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).