Development of a Coupled Eulerian-Lagrangian (CEL) Model for Broaching: Analysis of Cutting Forces and Chip Morphology

Broaching is a highly productive and precise machining process used to produce complex, high-quality surfaces. During the process, the cutting mechanisms differ significantly from conventional cutting, characterized by low uncut chip thickness, low cutting speeds and long encapsulated chips. Despite its importance, there are relatively few studies on broaching, particularly concerning numerical simulation. In this research, Coupled Eulerian-Lagrangian (CEL) method, which integrates both Lagrangian and Eulerian formalisms to address the issue of mesh distortion, was developed and applied. The results, including cutting forces evolution and chip morphology were compared with experimental ones, as well as with those from ALE and Lagrangian simulations.