Tool Design and Progressive Shape Formations During Electrochemical Broaching
The subject matter of this investigation involves the definition of progressive shape formations for a certain arbitrary tool design in the course of electrochemical broaching. The objective is to enable the designer allocate the appropriate parameters related to a broaching tool design as well as machining conditions, for attaining a reguired component configuration. The scope comprises the study of the progressive processed shapes for a sguare or triangular shape broaching tools. Comparison between experimental and analytical results proved the validity of the use of the side gap equation for predicting the processed profiles and evaluating the power consumption. The results show that the rounding-off angle is governed mainly by the tool end geometry being insensitive to its overall geometry. Improved conformity was found to be a result of the increase in both tool feed rate and approach and pyramidical angles. The results also indicate that for triangular tools, both concavity and rounding-off characterize the workpiece profile.
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