Estimation of Drag Finishing Abrasive Effect for Cutting Edge Preparation in Broaching Tool

In recent years, cutting edge preparation became a topic of high interest in the manufacturing industry because of the important role it plays in the performance of the cutting tool. This paper describes the use of the drag finishing DF cutting edge preparation process on the cutting tool for the broaching process. The main process parameters were manipulated and analyzed, as well as their influence on the cutting edge rounding, material remove rate MRR, and surface quality/roughness (Ra, Rz). In parallel, a repeatability and reproducibility R&R analysis and cutting edge radius r(e) prediction were performed using machine learning by an artificial neural network ANN. The results achieved indicate that the influencing factors on r(e), MRR, and roughness, in order of importance, are drag depth, drag time, mixing percentage, and grain size, respectively. The reproducibility accuracy of r(e) is reliable compared to traditional processes, such as brushing and blasting. The prediction accuracy of the r(e) of preparation with ANN is observed in the low training and prediction errors 1.22% and 0.77%, respectively, evidencing the effectiveness of the algorithm. Finally, it is demonstrated that the DF has reliable feasibility in the application of edge preparation on broaching tools under controlled conditions.