This research paper highlights the results of undergraduate student research work that has been sponsored by aerospace industry. It demonstrates a methodology of designing, building, testing and implementing a inspection instrument for the evaluation of broaching tool. The inspection of the broaching tool is done for the monitoring of the tool geometry and profile so that the dimensions of machining edges are maintained to standards. The results from this new instrument prove that the methodology developed is a viable solution for increasing accuracy, speed, and repeatability of critical broach attributes. Broaching is a manufacturing process which is very rapid, accurate and leaves a finish of good quality. This process is employed primarily in the automotive industry where parts are produced in large quantities and frequently to given dimensions within small tolerances. Aerospace industry utilizes the broaching manufacturing process to machine blade attachment slots in nickel alloy turbine and compressor disks. It is understood that the current methods for inspection of broach tools was slow and inaccurate. The results from this research prove that the measuring instrument developed is a viable solution for increasing accuracy, speed, and repeatability of measuring critical broach attributes. The critical attributes measured on the broach tool are: cutting edge measurement along the tooth profile, back off angle, lobe dimensions, and the pitch. While the method to inspect all broach tools is addressed, this research method focused on the complex geometry finisher cutters. These cutters usually consist of the last four broach sticks used in the machining process. The paper focuses on the methodology and results that include an instrumentation to accurately measure attributes of broach tools quickly, accurately, and with highly repeatable results. The instrument measures the dimensions with a tolerance of at ten microns, and angles to within half of a degree. The inspection of the broaching tool is done for the monitoring of the tool geometry and profile so that the dimensions of machining edges are maintained to standards. The results from this new instrument prove that the methodology developed is a viable solution for increasing accuracy, speed, and repeatability of critical broach attributes.
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