A model for the cutting force system in the gear broaching process

A mechanistic model for the cutting force system in a broaching process is developed. The broach geometry considered in the analysis is for a production operation used to produce an internal helical ring gear. The model for the force system is based on a description of the instantaneous chip load geometry and a relationship between the chip load and the three-dimensional cutting force system. The chip load geometry is based on the process kinematics and the involute-shaped cutting teeth of the broach. Shaping tests are performed to develop empirical equations for the cutting and thrust pressures. The model is validated through a comparison with actual forces generated during the production process.