Akula et al.

, International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Research Paper
DESIGN AND ANALYSIS OF BROACH TOOL FOR
SPLINES
Malyadri Akula1, K.Chandra Sekhar2, Akula Nagendra3

Address for Correspondence

1
M.Tech Student,2 Associate Professor, 3 Professor, Department of Mechanical Engineering
1,2
QIS College of Engineering & Technology, Ongole
3
Samskruthi college of engineering, Hyderabad, Andhra Pradesh, India
ABSTRACT
Broach tool is a multi point cutting tool consisting a bar having surface containing a series of cutting teeth or edges which
are gradually increase in size from the starting or entering and to the rear end. Broaches are used for machining either
internal or external surface (i.e sizing of holds and cutting of serrations, straight or helical planes, gun rifling and key ways).
In this work a broach cutting tool is design to perform internal splines of synchro shuttle transmission for flange coupling.
In the present work Broach cutting tool is going to be designed to generate internal splines for Synchro shuttle transmission
which is suitable for Jacob Cycerll Byford 3D TURBO with the help of vertical broaching machine. A ‘C’ program will be
generated to identify various parameters of broach tool. A sophisticated ANSYS 11 (FEM) package shall be used to analyze
the displacements and stresses present in broach cutting tool. All the stress distributions and displacements shall plotted
against rise or tooth for different pitch and rake angles.
KEYWORDS: Design;Analysis; Broach Tool; Splines
1.0 INTRODUCTION rejections of the part or the tool. At the most it may
Broaching is a method of removing metal by a tool result in reduced life or lesser productivity. But in
that has successively higher cutting edges in a fixed case of the Broaches such a mistake may result in the
path and each tooth removes a predetermined amount breakage of the tool or rejection of the parts.
of material. Broaching has a wide range of Therefore broach design is an activity demanding
applications with several advantages over other sound experience and expertise.
machining processes. Broaching is rapid and Broach tool design consists of cutting elements, pull
efficient because both roughing and finishing can be end, rear end, front pilot, rear pilot, total length of the
done in a single pass, close tolerances are added tool, specific cutting force, force required for
advantages of the process. Except in the case of gear, broaching and strength of the tool.
broach is always moves forward in a straight line. 2.1 Cutting Elements
Hence the Broaching surface must be parallel to the The cutting elements of broach teeth are shown in
axis of tool travel. Figure.1. The face angle or hook angle () is
In the present work, design and analysis is carried out equivalent to the rake angle of single point tools and
for broach tool to perform internal splines of Synchro depends upon the material to be cut, the back off
shuttle transmission for flange coupling in Jacob angle () is chosen independent of work material to
Cycerll Byford-3D TURBO. The Synchro shuttle ensure good cutting conditions by reducing friction
transmission coupling flange is assembled on the between the tooth flank and the machined surface.
pinion shaft of gear box over splines and the other The land (g) provides the necessary strength for the
end of spigot is fixed to a universal joint. The flange tooth the chip space with radius (r – Gullet) facilitates
is used to transmit power from Gear Box to rear axile formation of chips into convenient shape and
through propeller shaft assemblies. Compared to accommodate the trapped chips the distance P
other machining operations, like slotting & shaping, between successive teeth is pitch, the difference in
broaching operation attains better accuracy, surface height of successive teeth forms cut per tooth or rise
finish and productivity for generation of internal per tooth.
splines.
The program is developed in ‘C’ Language for the
design of broach tool to obtain different parameters
like pitch, land, length of the tool, specific cutting
force & total broaching force for internal splines.
The program developed can be used to design any
type of the broaching tool for internal splines with Figure.1: Cutting elements of Broach
straight sides. Modes of cutting in broaching :
A sophisticated ANSYS 11 FEM package is used to (a) Full-form; (b) generation; (c) staggered;
analyze the stresses developed in cutting tooth. The (d) Alternate and multiple-sided
forces obtained for various parameters are applied on
the tooth to analyze the stresses and deflections.
Material considered for broach tool is high speed
steel M2 type. The machine for performing the
broaching operation is taken for a capacity of 1200
mm stroke length and 16 tons pulling force.
2.0 BROACH TOOL DESIGN
When compared to other Cutting Tools for Instance a
milling cutter, a broach is many times costlier. Any
small error committed in the design of a milling
cutter or a turning tool may not lead to the total Figure.2: Design for chip space in a broach

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 Akula et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

3.0 DESIGN PROCEDURE The rake angles of tool for 12o, 15o and 18o and pitch
After observing the work piece drawing relevant data of 9.68 mm, 10.46 mm and 11.23 mm are considered
is as under: for various values of depth of Cut (rise / tooth), the
Major Dia. D = 50.5 mm values of length of the tool over teeth, total length of
Minor Dia. D = 43.5 mm the tool, specific cutting force, total Broaching force
No. of splines S = 16 and load per tooth were recorded with the help of ‘C’
Spline width W = 5.0 + 0.01 mm program and the results are tabulated.

Figure.4: Variation of specific cutting force Vs

Rise/Tooth

Figure.3 Heavy Earth Equipment Gear Box Flange

Coupling
length of the splines I = 60 mm
Handness = 200 BHN
Ultimate tensile
Strength = 65 kg / mm2 for En 8m material
Table.1: Specifications of the Tool Figure.5: Variation of Total broaching force Vs. Rise/
Tooth

Figure.6: Variation of Total broaching force Vs.

Rise/tooth

4.0 DESIGN OF BROACHING TOOL FOR

INTERNAL SPLINES
4.1 Results
INPUT DATA:

Figure.7: Variation of Total broaching force Vs.

Rise/tooth
4.2 Displacement and stresses distribution of a
cutting tooth
OUTPUT DATA:

Figure.8: Cutting tooth with Finite elements

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 Akula et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

5.0 CONCLUSIONS
• The variations of cutting force per tooth is
constant for different pitch values, for a
given rake-angle.
• The total Broaching force varies with pitch
value for a given rake angle due to the
variations in number of teeth in engagement.
• The stress plot against depth of cut shows
uniform increase of stresses, the stresses are
Figure.9: 1st Principle stress distribution S1 increasing with decreasing of rake angles
Table:2 due to higher cutting forces.
• The deflection of the tooth is higher for
higher rake angle. This is because of the
reduction in included angle of the tooth.
• The rake angle influencing the total
broaching force and force on cutting tooth.
Hence very care should be taken while
resharpening the tooth tool to maintain the
designed rake angle on the profile of the
tooth.
REFERENCES
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Figure:10: Variation of stress SY Vs Rise/tooth

Figure:11: Variation of stress SX Vs. Rise / Tooth

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