During the broaching process, the workpiece and the broach undergo deflections owing to the large forces involved. The final shape of the broached component is a consequence of the net effect of tool-work deflections during broaching. In this paper the final shape arrived at from the FEM analysis is compared with the actual shape after broaching. The shape produced by cutting teeth and burnishing teeth are separately discussed with the help of finite element analysis. The experimental and theoretical results have been analysed with a view to arriving at useful conclusions related to the broaching process and the broach design. Some relevant discussion is also included.
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