Calculation and design of a shaped cutter and keyway broach.

Design a shaped prismatic cutter for machining a workpiece with preparation for subsequent cutting. Determine the cutter profile graphically. The workpiece material is a rod with a diameter of D made of steel 45 with σ = 750 MPa (~ 75 kgf/mm²).

Design a keyway broach for the keyway of a gear wheel part.

                                     Contents

INTRODUCTION 4

1. Calculation and design of shaped tools 6

1.1 General information 6

1.2 Calculation of the shaped prismatic cutter 8

1.3 Selection of design parameters for the shaped cutter. 9

1.4 Correction calculations 10

1.5 Setup scheme for the shaped cutter 12

2. Calculation of the keyway broach 14

2.1 General information 14

2.2 Initial data 16

2.3 Feed per tooth 16

2.4 Calculation of the pitch of cutting teeth 17

2.5 Depth of chip grooves 18

2.6 Rake angles 20

2.7 Clearance angles 20

2.8 Other dimensions of tooth profiles and chip grooves 20

2.9 Selection of shank dimensions 21

2.10 Calculation of total cutting force 22

2.11 Strength check of the broach 23

2.12 Determination of total allowance for broaching 24

2.13 Determination of the pitch of calibrating teeth 24

2.14 Determination of the height of calibrating teeth 24

2.15 Determination of the number of calibrating teeth 24

2.16 Compilation of a table of broach tooth diameters 25

2.17 Determination of the nominal value of tooth width 26

2.18 Determination of the shape, sizes, quantity, and arrangement of chip-breaking grooves 26

2.19 Determination of other dimensions of the broach 27

2.20 Setup of the broaching operation 28

Conclusion  

References