Patent ID: 8000942

Claim:
A method for designing a broaching tool comprising the steps of: a) providing a geometry of a slot to be broached; b) providing a material dependent initial minimum tooth rise for a broach tool that includes multiple broach inserts, wherein the broach inserts include finish, semi-finish and rough broach inserts, and determining the initial minimum tooth rise for the finish broach inserts, wherein the initial minimum tooth rise is greater than 30 μm for a coarse-grained alloy material with an average grain size larger than 25 μm, and wherein the initial minimum tooth rise is greater than 32 μm for a fine-grained alloy material with an average grain size smaller than 25 μm; c) calculating a number of broach inserts and teeth per insert based upon steps a) and b); d) solid modeling the broach inserts from step c); e) calculating the stresses on the broach tool and deformation of the slot; f) determining whether the slot dimensions are within desired specifications based upon step e); and g) revising the broach tool if the slot is outside the desired specifications, and performing steps c)-g) until the slot is within desired specifications; and h) manufacturing a broaching tool with design characteristics of the broach tool resulting from performing step a)-g).