Optimization of surface roughness in broaching

The broaching process is used to generate high quality surfaces in very short times. In order to improve the understanding of the evolution of surface quality in broaching, a sensitivity study of the influence on the surface roughness of several broaching parameters dealing with the tool design, the cutting conditions or the workpiece material was performed. Forces and chip formation have also been analyzed so as to highlight the surface roughness generation. This paper shows how the process parameters (such as cutting speed or lubrication), tool design (rise per tooth, tooth angles, substrate material), and workpiece material affects the surface roughness.