Abstract: A broaching apparatus includes a first tooth having a front face, a rear face opposite the front face, and a first cutting surface have a lobed shape extending along a first side of the first tooth between the front face and the rear face. A first interface defined between the first cutting surface and the front face is offset relative to a second interface defined between the first cutting surface and the rear face in a direction that is substantially perpendicular to an axis of tooth movement for broaching operations to provide tool clearance rearward from the first interface. A method of making a broach cutter is further provided.

Abstract: A broaching apparatus includes a first tooth having a front face, a rear face opposite the front face, and a first cutting surface have a lobed shape extending along a first side of the first tooth between the front face and the rear face. A first interface defined between the first cutting surface and the front face is offset relative to a second interface defined between the first cutting surface and the rear face in a direction that is substantially perpendicular to an axis of tooth movement for broaching operations to provide tool clearance rearward from the first interface. A method of making a broach cutter is further provided.

Abstract: This disclosure relates to a design methodology used in manufacturing a broaching tool for cutting slots in aerospace disk applications. The method includes modeling geometry of the slot and the broach tool, which is based upon an initial minimum tooth rise that is determined empirically for the particular disk material. The number of broach inserts and teeth per insert is calculated, and the broach inserts are modeled. The stresses and deformation of the lug are calculated in a finite elements environment based upon simulated incremental broach tool movements. If the lug is not within specifications based upon design constraints, then the broach tool is revised and the simulations are repeated until the slot is within the desired specifications.

Abstract: This disclosure relates to a design methodology used in manufacturing a broaching tool for cutting slots in aerospace disk applications. The method includes modeling geometry of the slot and the broach tool, which is based upon an initial minimum tooth rise that is determined empirically for the particular disk material. The number of broach inserts and teeth per insert is calculated, and the broach inserts are modeled. The stresses and deformation of the lug are calculated in a finite elements environment based upon simulated incremental broach tool movements. If the lug is not within specifications based upon design constraints, then the broach tool is revised and the simulations are repeated until the slot is within the desired specifications.