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 1 Address for Correspondence 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 Broaching is a method of removing metal by a tool that has successively higher cutting edges in a fixed path and each tooth removes a predetermined amount of material. Broaching has a wide range of applications with several advantages over other machining processes. Broaching is rapid and efficient because both roughing and finishing can be done in a single pass, close tolerances are added advantages of the process. Except in the case of gear, broach is always moves forward in a straight line. Hence the Broaching surface must be parallel to the axis of tool travel. In the present work, design and analysis is carried out for broach tool to perform internal splines of Synchro shuttle transmission for flange coupling in Jacob Cycerll Byford-3D TURBO. The Synchro shuttle transmission coupling flange is assembled on the pinion shaft of gear box over splines and the other end of spigot is fixed to a universal joint. The flange is used to transmit power from Gear Box to rear axile through propeller shaft assemblies. Compared to other machining operations, like slotting & shaping, broaching operation attains better accuracy, surface finish and productivity for generation of internal 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 straight sides. A sophisticated ANSYS 11 FEM package is used to analyze the stresses developed in cutting tooth. The 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 IJAET/Vol. IV/ Issue I/Jan.-March., 2013/06-08 rejections of the part or the tool. At the most it may result in reduced life or lesser productivity. But in case of the Broaches such a mistake may result in the breakage of the tool or rejection of the parts. Therefore broach design is an activity demanding sound experience and expertise. Broach tool design consists of cutting elements, pull end, rear end, front pilot, rear pilot, total length of the tool, specific cutting force, force required for broaching and strength of the tool. 2.1 Cutting Elements The cutting elements of broach teeth are shown in Figure.1. The face angle or hook angle () is equivalent to the rake angle of single point tools and depends upon the material to be cut, the back off angle () is chosen independent of work material to ensure good cutting conditions by reducing friction between the tooth flank and the machined surface. The land (g) provides the necessary strength for the tooth the chip space with radius (r – Gullet) facilitates formation of chips into convenient shape and accommodate the trapped chips the distance P between successive teeth is pitch, the difference in height of successive teeth forms cut per tooth or rise per tooth. Figure.1: Cutting elements of Broach Modes of cutting in broaching : (a) Full-form; (b) generation; (c) staggered; (d) Alternate and multiple-sided Figure.2: Design for chip space in a broach Akula et al., International Journal of Advanced Engineering Technology 3.0 DESIGN PROCEDURE After observing the work piece drawing relevant data is as under: Major Dia. D = 50.5 mm Minor Dia. D = 43.5 mm No. of splines S = 16 Spline width W = 5.0 + 0.01 mm E-ISSN 0976-3945 The rake angles of tool for 12o, 15o and 18o and pitch of 9.68 mm, 10.46 mm and 11.23 mm are considered for various values of depth of Cut (rise / tooth), the values of length of the tool over teeth, total length of the tool, specific cutting force, total Broaching force and load per tooth were recorded with the help of ‘C’ 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 IJAET/Vol. IV/ Issue I/Jan.-March., 2013/06-08 Akula et al., International Journal of Advanced Engineering Technology Figure.9: 1st Principle stress distribution S1 Table:2 table shows rise/tooth mm, load/tooth, stress SX, stress SY, stress SXY, stress S1, stress S2, N/mm2 and deflection, mm Table:3 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 increasing with decreasing of rake angles 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 1. 2. 3. 4. Table shows rise/tooth mm, load/tooth, stress SX, stress SY, stress SXY, stress S1, stress S2, N/mm2 and deflection, mm Table:4 5. 6. 7. 8. 9. 10. Table shows rise/tooth mm, load/tooth, stress SX, stress SY, stress SXY, stress S1, stress S2, N/mm2 and deflection, mm 11. 12. 13. Figure:10: Variation of stress SY Vs Rise/tooth Figure:11: Variation of stress SX Vs. Rise / Tooth IJAET/Vol. IV/ Issue I/Jan.-March., 2013/06-08 E-ISSN 0976-3945 U Kokturk, E. Budak , “Optimisation of Broaching Tool Design” Inteligent Computation in Manufacturing Engineering - 4261- 4273. S.P.Mo,D.A.Axinte,T.H.Hyde,N.N.Z.Gindy, “An example of selection of the cutting conditions in broaching of heat resistance alloy based on cutting forces, surface roughness and tool wear”, Journal of Material Processing Technology,Vol 160 pp.382389,2005. Dragas A. Axinte, “Approach into the use of Probablistic neural networks for automated classification of tool malfunctioning in broaching”, International Journal of Machine Tools and and Manufacture 46 (2006) 1445-1448 Yuan Yuefeng,Chen Wuyi,Gao Liansheng, “Tool Materials Rapid Selection Based on Initial Wear”,Chinese Journal of Aeronautics,23(2010)386382 E.A.Markin “Investigation of the hydro-mechanical system of broaching machine”, Journal of Machine tools and manufacture Vol 37 pp 11-15,1966. Drozda, J.T., 'Broaching Planing, Shaping and Slotting', Tool and Manufacturing Engineering Handbook, Vol. 1, Mcfiraw-Hill, 1983. Juvinall, R. C., Stress, Strain and Strength, Mcflraw Hill, 1982. Collins, J.A., 'Failure of Material in Mechanical Design', Analysis prediction prevention, John Wiley and sons, 1981. Engineering Modelling System, Reference Manual, Integraph Corporation, 1994. Finite Element Modeller, Operators Training Guide, Integraph Corporation, 1994. Hindustan Machine Tools limited, Production technology, Tata McGraw Hill, New Delhi, 1987. Zeid, I., CAD/CAM Theory and Practice, McGrawHill, 1991. Burden, W., Broaches and Broaching, Broaching Tool Institute, 1944.