Broaching is machining process for removal of layer of material of desired width and depth usually in one stroke by bar type cutter with series of cutting edges. Broaching enables remove the whole material in one stroke only by the gradually rising teeth of cutter called broach. Due to the process geometry broaching tool is the most critical parameter of broaching process. Therefore optimal design of tools is needed prediction of stress with respect to various parameter of tool in order to improve the productivity of the process. In this paper, a methodology is presented for prediction of stress with respect to variation in variables . The method has also been implemented on computer code. Matlab code was written in an m- file which helped us to determining the stress with respect to force, height, thickness, face angle, gullet radius and land.

Broaching, Optimization, Tooling