This study investigates the effect of cutting-edge radius on surface integrity during dry broaching of Inconel 718 at 20 m/min. Experiments and simulations were used to analyse the effect of cutting radius and rise per tooth (RPT) on residual stresses using X-ray diffraction (EDX) and hole drilling, supplemented by Vickers microhardness and SEM. The results show that radii greater than 15µm produce a critical transition: while they increase microstructural deformation and surface tensile stresses, they also produce subsurface compressive stresses that improve component integrity. These findings provide important guidelines for optimizing tooling and extending the service life of critical components broached in nickel alloys.
Science Journal 