Broaching: Cutting tools and machine tools for manufacturing high quality features in components

Broaching is a unique machining process with high accuracy and surface quality, which is employed in mass and batch production for the manufacture of components with highly complex geometries. It involves the use of multiple-edged complex tools in which the cutting edges are arranged with an offset also known as “rise per tooth” that determines the depth of cut per tooth. This paper presents the state-of-the-art of both the experimental and modelling aspects of broaching, and identifies the most important features related to this machining process. This includes a critical assessment of specifically designed broaching setups and their applicability and/or limitations compared to the machines used in industry. Contributions from academia and industry are included to support a comprehensive report of recent advances, as well as a roadmap for future developments.