An analysis of the effects of burnishing in internal broaching

The finite element analysis gives the stresses and deflections of the broach and workpiece while cutting and burnishing. This has been achieved by developing a suitable finite element program for solving linear and non-linear material behaviour problems. The broach has been considered to behave elastically. In case of burnishing, the stresses on the workpiece result in yielding, and hence, non-linear material behaviour is considered for the workpiece. The program has been further modified to compute residual stresses on the broached component. The movement of a single burnishing tooth through the workpiece is simulated in a step-by-step manner, leading to residual stresses on the broached surface. The burnishing tooth and corresponding portion of the workpiece are modelled using FEM. The effect of tool-work interference and the ratio of radial to axial force on the stresses and deflections while burnishing have been studied. The residual stresses left behind on the broached component have been analytically evaluated.