A geometrical and mechanistic generalized model for complex shape broaching of super alloy

The aircraft engine disks are highly critical parts. It is required for blade assembly to obtain high quality slots after broaching. Because of the complexity of the slot shapes, different problems are induced such as the cutting geometry, the broach design and the difficulties to evaluate the forces applied on the tool. To deal with this problematic, this article presents a geometrical and mechanistic model taking into account the various geometrical parameters of a form broach (pitch, shift, profiles and cutting geometry of the half teeth) to determine the cutting forces. The methodology of the cutting edges discretization and an oblique cutting law have been used. Several simulations made with this generalized model are presented to understand the impacts of the variation of the tool’s geometrical parameters on the cutting forces evolution in order to improve the broaching of complex shape