Innovative Lagrangian Model of Broaching to Reduce CPU Time

Broaching is a productive and accurate process generating complex surfaces with high quality. In this process, cutting mechanisms occurring are very specific regarding conventional cutting (small uncut chip thickness, low cutting speeds, long encapsulated chips). However, few research have been conducted on this process and in particular in the topic of simulation. For that, an original Lagrangian model that enables to simulate long cutting time by means of an iterative procedure has been developed. Cutting forces, temperatures evolutions and chip morphology obtained with this model have been compared with results from experimental tests and ALE simulations.