A.V. Pradeep, K. Ram Prasad, T.

Victor Babu / International Journal of Engineering Research

and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074

Design And Finite Element Analysis Of Broaching Tools

A.V. PRADEEP*, K. RAM PRASAD**, T. VICTOR BABU***
*(Department of Mechanical engineering, SANKETIKA VIDHYA PARISHAD, VISAKHAPATNAM-41)
** (Department of Mechanical engineering, SANKETIKA VIDHYA PARISHAD, VISAKHAPATNAM-41)
*** (Department of Mechanical engineering, SANKETIKA VIDHYA PARISHAD, VISAKHAPATNAM-41)

ABSTRACT
Broaching is a machining process in parts, and stampings. Even though broaches can be
which a cutting tool, having multiple transverse expensive, broaching is usually favoured over other
cutting edges, is pushed or pulled through a hole processes when used for high-quantity production
or surface to remove metal by axial method. runs. The interesting aspect of broaching is that the
Broaching, if properly used, is a highly feed is built directly into the broach (cutting tool) and
productive, precise and extremely versatile has the machine provide only one function -speed, for
process. It is capable of production rates as much metal removal, unlike in the other processes such as
as 25 times faster than any traditional metal milling, planning, etc., where the speed and feed are
removing methods. Objectives are to lower the the metal removing functions that machine tool is
cost of design process by reducing the time required to provide.
required to design and fabricate broach tools
which was materialized by the parametric design
of the broach, where the design intent of the
broach tool geometry is captured. Another
objective is to predict the strength characteristics
of the broaching tools in the preliminary stage for
the tool engineer which was to evaluate the stress
characteristic of the broach tool subjected to the
cutting conditions. This would be useful for the
tool engineer to keep a check on the tool's strength
characteristics during every stage of the tools life
and also on improving its characteristics during
the wear out period. This was achieved by BROACH GEOMETRY
meshing and performing analysis using the Finite
Element Modeller package called IIFEM. The 2. OBJECTIVE
model built from the parametric design was The first objective was materialized by
utilized to make a finite element model and the parametric design of the broach, where the
analysis was performed to predict the stress and design intent of the broach tool geometry is captured.
deflection in the tool. This would reduce time to A geometrical relationship is developed on the
design different broaches. By just changing the broach tool geometry which is very flexible and can
dimensions and the constraints when required, a be altered for most of the tools with very little user
new broach can be designed, thus allowing a lot of intervention. This was achieved using the software
flexibility in the design. Further the solid model called I/EMS, a design and modelling product from
can be used to perform the finite element analysis Intergraph Corporation.
which would help in knowing the characteristic of The second objective was to evaluate the stress
the broach tool under various cutting loads. This characteristic of the broach tool subjected to the
would also assist in improving the performance of cutting conditions. This would be useful for the tool
the tool. engineer to keep a check on the tool's strength
characteristics during every stage of the tools life and
1. INTRODUCTION also on improving its characteristics during the wear
Broaching is a machining process that uses a out period. This was achieved by meshing and
toothed tool, called a broach, to remove material. performing analysis using the Finite Element
Broaching is used when precision machining is Modeller package called I/FEM. The model built
required, especially for odd shapes. Commonly from the parametric design was utilized to make a
machined surfaces include circular and non-circular finite element model and analysis was performed to
holes, splines, keyways, and flat surfaces. Typical predict the stress and deflection in the tool.
work pieces include small to medium sized castings,
forgings, screw machine

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A.V. Pradeep, K. Ram Prasad, T. Victor Babu / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074

3. FINITE ELEMENT ANALYSIS

3.1. INTRODUCTION- This chapter Nodes : 4744
focuses on the concept of finite element analysis and
the development of finite element model and analysis Brick Elements : 3472
of a round hole broaching tool, performed to predict
the affects of maximum force on the cutting teeth Wedge Elements : 480
geometry. The static analysis was performed on the
broach teeth to check the maximum stress, the teeth 3.3.3. OCTAGONAL BROACH
can withstand before failing. Also the analysis was The solid model generated had a complex shape, so
carried out to simulate the deflection, the broach teeth the model for finite element generation was
are subjected to during the cutting operation, which approximated at the back angle and front angle radius
forms criteria as whether the amount of tolerance on in the octagonal shape vicinity. It was approximated
work piece is being met. The finite element modeling to shape close to the one which would be generated
and analysis was done using the Intergraph's Finite with a finite element mesh and the integrity of model
Element Modeler (I/FEM) which is integrated with was maintained. This model meshed using auto mesh
EMS. The broach teeth geometry which might which places tetrahedron elements.
change slightly due to the wearing of the tool after The model contains
repeated cutting operations, can be modified and the
rigidity of the teeth can be analyzed thus keeping a
thorough observation on the tool which helps Nodes : 1860
increase the tool life by taking proper care when the Brick Elements : 6502
chances of failure is imminent due to fatigue.
3.2. FEM FOR BROACH TOOLS- More appropriate 3.4. MATERIAL PROPERTY- The finite
analytical approach can be made to calculate the element models are assigned the material
stress distribution and check the performance, shape properties which are the physical properties of
and loading factors of the teeth. Only the broaching the model.
teeth were analyzed as the other parts such as the pull The properties assigned to the model were:
end, follower end and shank length are not subjected
to the force that broach teeth are subjected to. Material Type : Isotropic
Moreover, there is more probability that a broach Material Name : SAE Steel 4140
may fail at its teeth during the cutting operation. So Young’s Modulus :
only the broach teeth were modeled for analysis.The 3.0*E + 7 Psi or 206884*E + 6 N/m 2
finite element method breaks the broach teeth Poisson’s ratio : 0.26
geometry into a specified number of elements formed Maximum Yield Stress :
from nodes. These groups of elements represent the 91000 psi or 627.42 * E + 6 N/m2
model through the finite element mesh. The process
of generating the finite element mesh is meshing. The material can be created using the Create
3.3. MODEL DESCRIPTION Material command which invokes the form
3.3.1. ROUND HOLE BROACH driven database. The above mentioned
The mapped mesh on the broach teeth profile was properties are typed in the form. The material
rotated 360 degrees along its axis with 12 sectors. can be placed using Place Material command.
This was done using the rotate mesh option in the The material properties were placed on all of
mapped mesh generation menu. Tetrahedron the elements.
elements were used for meshing purposes.
The model contains 3.5. BOUNDARY CONDITIONS- A boundary
condition is a specific physical limit - an action
Nodes : 1587 for a restrain – applied to the model. The
boundary conditions are used in such a way that
they represent the motion of the broach model
Wedge Elements : 5989
under cutting operation. The boundary
3.3.2. FLAT BROACH
conditions used in this analysis are the
The mapped mesh on the broach teeth profile was
constraints and forces. In this research three
projected to a distance equivalent to the width of the
different types of models were analyzed. They
flat broach using the Project mesh option in the
are round hole, flat and octagonal broach tools.
mapped mesh generation menu.
Three different load cases were used and they
The model contains
are Maximum force, required force and the
intermediate force. The boundary conditions
applied to the tools can be visualized from the
figures given below.
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A.V. Pradeep, K. Ram Prasad, T. Victor Babu / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074
Three different load cases for these models. The
forces were placed on the nodes that formed on the
cutting edges of the tool. The magnitudes of the
forces were placed on the nodes in the X-direction
which is usually the case for these types of model
since they follow a linear cutting pattern. The force
computed was evenly distributed on t he cutting teeth
by dividing it with the number of nodes on the
cutting edge.

 Round Hole broach:

The round hole broach cutting edges had 12 nodes at

equal distant on them. The force computed was
divided by 12 and the resulting force was placed on
each of these nodes.

Maximum Force:
The maximum force that was placed was calculated
as follows:
F(max) = A*Y

Where,

F= force in lbf
Fig. 1 Fig. 2 A= area of min cross section
Y= tensile tool strength of the material
Fig. 1 : Boundary Condition on Flat Broach The force that was computed from above was:
Fig. 2 : Boundary Condition on Round Broach 32275.265 lbf
3.5.1. CONSTRAINTS
The movement of nodes along all the six degrees of Required Force:
freedom can be controlled by using this feature in The force required for a broach operation is
finite element method. The procedure for computed as follows:
constraining the three models are discussed below F(reqd) = 3.14 * N *D * R*C
 Round Hole Broach: Where,
Since only the cutting teeth were modeled, the first N= no. of teeth in contact = 3
surface which begins before the first tooth and the D= starting hole diameter = 1in or 0.0254 m
last surface after the finishing tooth were constrained. R= chip per tooth roughing =
This means that the broach teeth are fixed at the two 0.001006 in or 2.5 * E - 5 m
ends and movement in any direction is prevented. These were calculated assuming that three teeth are
The nodes that were in the planes at the two ends in contact at a time.
were constrained in all the degrees of freedom. This
was done from the I/FEM by using the Command The force computed for the roughing teeth were:
Place Constraint on the node and identifying the 947 lbf or 4214.15N
nodes existing those planes. The force computed for semi-finishing were: 106.495
lbf or 473.90275N
 Flat Broach:
The bottom surface of the flat broach is held by the Intermediate Force:
tool holding fixture and is either pulled or pushed This force was deduced after the above two
along the work piece or is held stationary and the operations. The main criteria considered in this case
work piece is passed over it. All the nodes that were were that this force when applied to the broaching
present in the bottom surface of the model were teeth would not result in the yielding of the tool. This
constrained in all directions. was done by hit and trial method and the safe load
that would result in the below the yield stresses on
3.5.2. FORCES APPLIED the broach was deduced. This force computed is valid
only for the type of model analyzed. This value
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 A.V. Pradeep, K. Ram Prasad, T. Victor Babu / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074
changes for different tools with different material and F(reqd) W *N * Cd * C
geometry backgrounds. Where,
W=Length of the tooth=1.5in or 0.0381m
The force reduced for the round hole broach in this N=Number Of Teeth in Contact= 3
design was: 5880lbf or 26166 N C=Broaching Constant=
450000 Psi or 310.26*E+6N/m 2
 Octagonal Broach: Cd=chip per tooth roughing=
Push type broach geometry was used for the 0.0013 in or 3.302 * E–5m
modeling of an octagonal broach. The model was The force computed for the roughing teeth were:
meshed using the Auto meshing option because of its 877.5 lbf or 3904.875N
complex geometry. The forces were applied on the The force computed for semi-finishing were: 75 lbf
nodes that existed on the cutting edge. These were or 333.75N
equally distributed among the nodes.
Maximum Force: Intermediate Force:
The maximum force that can be applied on a push Just like as in round hole broach, this force which is
broach is given by: an intermediate value between the maximum force
F(Max) = (Y *D4 )/L2 applied and required force. This force again is for the
Where, particular model which would result in the values
Y=Yield Strength of the tool= 91000 psi or below the yield stress and can act as a reference value
627.42*E+6N/m2 as far as the forces on the broach tool resulting in
D=Minimum root diameter L/2=2.676 in or below the yield point stress are concerned. This was
0.0679704 m deduced by trial and error method. Due to the limited
L=Length from push end to the first tooth= memory requirements for the model, not many
8.59 in or 0.218186m iterations could be done for the flat broach.
The force computed was: The force computed was:
63241.1 lbf or 284584.95 N 4500lbf or 20025N

Required Force: 4. RESULTS USING ANSYS

The force required for octagonal broach which is I/FEM provides the information of various
same as the one for round hole broach is computed as stress values and displacements for all the elements
follows: and nodes in X, Y and Z directions. The failure
F (reqd) =3.14*N*D*R*C criteria used by I/FEM is Huber-von-Mises-Hencky
Where, theory.
N= no. Of teeth in contact Failure is predicted to occur in the multi-axial state of
D= starting hole diameter stress when the distortion energy per unit volume
R= chip per tooth cutting becomes equal to or exceeds the distortion energy per
These were calculated assuming that three teeth are in unit volume at the time of failure in a simple uniaxial
contact at a time. test using a specimen of the same material.
The force computed for the roughing teeth were: On analysis it was revealed that the maximum Von
2650lbf or 11925N Mises stress was on the elements that were at the core
The force computed for semi-finishing were: 480 lbf diameter of the round hole broach. The stress
or 2182.5N distribution on the teeth increased progressively from
the top element where the force was applied to the
 Flat Broach: elements at the core diameter. The stress distribution
follows the same trend for all the cases. The
Maximum Force: maximum stress value occurred at the very first teeth,
The maximum force a broach can withstand is which implies that the first tooth is subjected to
computed by maximum stress and force during the entire
operation.
F (max) = A*Y = L *W * Y. The analysis also resulted in maximum displacement
Where, the teeth undergo during the cutting operation. This
A= area of min. Cross section= can be used as a criteria as to examine whether the
6.4516 x 10-4 m2 tolerance on the work piece is being met. The
L= length of tooth= 1.5 in or 0.0381 m maximum displacement did not exceed 0.003 in.
W= width of tooth= 0.2 in or 0.00508m The result would change for different materials, i.e.,
The Force computed was: once the Young's Modulus and Poisons ratio is
27300lbf or 122850N changed, the analysis would result in different values
Required Force: corresponding to the type of material.
The required force for a flat broach is computed by The following tables reports the maximum and
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 A.V. Pradeep, K. Ram Prasad, T. Victor Babu / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074
minimum stress and displacement values for the three 4.2. DISPLACEMENT TABLES
different cases discussed in the preceding chapter for 4.2.1. Displacements in the Round Hole Broach
the round hole, octagonal hole and flat broaches DISPLACEM
respectively. These tables are followed by the plots of ENT CASE 1 CASE 1 CASE 1
Von-Mises stress distribution for the required load
case in figures for the different broach models. The MAXIMU
stress plots show that the first tooth of the broach has M in 1.07* E-02 4.6* E-04 3.0* E-03
the maximum stress value at its core diameter.
2.7178 x E- 1.684 x E-
4.1. STRESS TABLES m 04 05 7.62 x E-05

4.1.1. Stresses in the Round Hole Broach: MINIMU

M in 0.0 0.0 0.0
STRESS CASE 1 CASE 2 CASE 3

1.246 * m 0.0 0.0 0.0

Psi 8.90 * E+05 E+04 8.3 * E +04

MAXIMUM 54613. * 85.9 * 572.2 * 4.2.2. Displacements in the Octagonal Hole Broach
2
N/m 7 E+06 E+06 E+06
7.316 * E 1.28 *
Psi +03 E+02 1.77 * E+03 DISPLACEM
ENT CASE 1 CASE 2 CASE 3
MINIMUM 8.82 * 12.203 *
N/m 2 50.44 * E+06 E+09 E+06 3.706 * E -
4.1.2. Stresses in the Octagonal Hole Broach MAXIMU in 02 1.31 * E-03 -
CA M 9.41324 x 3.3274 x E-
SE
m E-04 05 -
STRESS CASE 1 CASE 2 3

MAXIMU in 0.0 0.0 -

M Psi 1.98*E+06 8.3*E+04 - MINIMU
M
13651.70 * 572.26 *
m 0.0 0.0 -
N/m2 E+06 E+06
MINIMU
M Psi 324.9 13.75 -
4.2.3. Displacements in the Flat Broach
2.24 * 0.094 *
N/m2 E+06 E+06 DISPLACEME CASE CASE
NT CASE 1 2 3
4.1.3. Stresses in the Flat Broach
3. 1.2 * 10 E -
MAXIMUM 9.63 * E – 03 0 * 10 E – 03
in 0
CASE
STRESS CASE 1 CASE 2 3 4

MAXIMU 5.06 * E 6.54 * 2.4460 7.62 x E- 3.048 x E-

M Psi +05 1.50 * E +04 E+04 2 x E- 06 05
m
04
3488.76 * 103.42 * 450.91 *
2
N/m E+06 E+06 E+06
0.
MINIMU 7.62 * E 3.374 *
MINIMUM in 0.0 0 0.0
M Psi +03 6.96 * E+02 E+02
0.
52.53 * 4.798 * 2.32 *
2 m 0.0 0 0.0
N/m E+06 E+06 E+06

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and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074

4.3.3. Von – Mises Stress for the required force for

the Flat Broach

4.4. ANALYSIS RESULTS OF BROACH TOOL

UNDER VARYING LAND WIDTH
4.3. FIGURES FROM ANSYS So far in this study, the geometry of the tool was kept
4.3.1. Von – Mises Stress for the required force for constant and was analyzed under varying loads. An
the Round Hole Broach extension of this study may be to analyze the tooth
behaviour under varying cutting teeth parameters,
such as the pitch, gullet depth, land width, face angle,
etc.,. The following table summarizes a brief analysis
in this direction which was performed by varying the
land width by 10%. A constant force of 948.312 lbf.
Were applied on the first three teeth for the three
different models. The stress levels reduced by 6.7%
when the land width was increased 10% from .156
inches to .172 inches. Similarly the stress levels
increased by 11.7 % when land width was reduced
10% from .156 inches to .140 inches.
4.4.1. Comparison of Maximum Stress for the three
cases

Iteration Iteration
Baseline 1 2

Maximum 9,36
Stress In PSI 6 8,734 10,460

In 64.57*E 60.219*E 72.11*E+

N/m 2 +06 +06 06
%
4.3.2. Von – Mises Stress for the required force for Change
the Octagonal Hole broach in
stress
from
baselin
e (+) 11.7
- (-)6.7% %

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and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074
Baseline : Land width of 0.156 inches or 3.9624 * E-
03 m

Iteration 1 : Land width of 0.172 inches or 4.368 * E-

03 m

Iteration 2 : Land width of 0.1404 inches or 3.56 * E-

03 m

The Von Mises stress distribution for the above

mentioned models can be seen from the figures given
below. The maximum stress occurs at the first tooth
for all the cases.
4.4.2. Von – Mises Stress for the Baseline Model

4.4.3. Von – Mises Stress for the Iteration 1 Model

5. CONCLUSIONS
The design of the broach using the
parametric modelling was addressed in this research.
This tool can be used for designing and modifying
the broaches of various types and this would reduce
time to design different broaches. By just changing
the dimensions and the constraints when required, a
new broach can be designed, thus allowing a lot of
flexibility in the design. Further the solid model can
be used to perform the finite element analysis which
would help in knowing the characteristic of the
broach tool under various cutting loads. This would
also assist in improving the performance of the tool.
4.4.4. Von – Mises Stress for the Iteration – 2 Model The analysis was performed on the three different
solid models which were generated by the parametric
modelling. The finite element model generated for
the round and flat broach were done by mapped
meshing while auto meshing was used for the
octagonal broach.
Three different load cases were used, the first one
being the maximum force the broach teeth can
withstand which was calculated based on the
formulae found in the literature.
The second case being the force required to do the
cutting operation. This was also calculated based on
the formulae found in the literature. The maximum
force case for both the models, round and flat were
resulting in stresses above the yield point.
The third load case which was used was the
intermediate force, which was basically done by the
hit and trial method to capture the value between the
maximum force and required force, that would result
in the stress values which are close to the yield. This
force can also be kept as a check point force, that
should not be exceeded for the cutting operations.
The octagonal broach was meshed using the
automatic option because of its complex geometry.
Only two cases were run for the octagonal broach as
the required force had resulted in the stress very close

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 A.V. Pradeep, K. Ram Prasad, T. Victor Babu / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 6, November- December 2012, pp.067-074
to the yield point stresses. The maximum stress
however had a very high stress value. The high stress
area were very small and occurred near the gullet
which was the same for the other models too. The
main concern in the octagonal broach was the stress
at the square teeth. Since the maximum force is
always taken by the first teeth, the stress
concentration is more on it. The octagonal teeth
usually starts at the end of roughing, and ends at the
finishing teeth. The stresses in these areas are much
below than the beginning few round hole teeth.

REFERENCES

Reference books:

1. Juvinall, R. C., Stress, Strain and Strength,

Mcflraw Hill, 1982.
2. Collins, J.A., 'Failure of Material in Mechanical
Design', Analysis prediction prevention, John
Wiley and sons, 1981.
3. Engineering Modelling System, Reference
Manual, Integraph Corporation, 1994.
4. Finite Element Modeller, Operators Training
Guide, Integraph Corporation, 1994.
5. Hindustan Machine Tools limited, Production
technology, Tata McGraw Hill, New Delhi, 1987.

6. Zeid, I., CAD/CAM Theory and Practice,

McGraw-Hill, 1991.
7. Burden, W., Broaches and Broaching, Broaching
Tool Institute, 1944.

Reference sites:
1. http://en.wikipedia.org/wiki/Boundary_value_pro
blem
2. www.sv.vt.edu/classes/MSE2094_NoteBook/.../n
um/.../history.html
3. http://en.wikipedia.org/wiki/Broaching_%28metal
working%29
4. http://www.generalbroach.com/internalbroaches.p
hp
5. http://www.dumont.com/resource-
center/standard-broaching-procedures-
guide/broaching-with-internal-hole-broaches/

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