IJE TRANSACTIONS A: Basics Vol. 33, No. 4, (April 2020) 657-667 Please cite this article as: P. Khanjanzadeh, H. Amirabadi, J. Sadri, Design of Broaching Tool Using Finite Element Method for Achieving the Lowest Residual Tensile Stress in Machining of Ti6Al4V Alloy, International Journal of Engineering (IJE), IJE TRANSACTIONS A: Basics Vol. 33, No. 4, (April 2020) 657-667 International Journal of Engineering Journal Homepage: www.ije.ir Design of Broaching Tool Using Finite Element Method for Achieving the Lowest Residual Tensile Stress in Machining of Ti6Al4V Alloy P. Khanjanzadeh a , H. Amirabadi* a , J. Sadri b a Department of Mechanical Engineering, University of Birjand, Birjand, Iran b Department of Computer Science & Software Engineering, Concordia University, Montreal, Canada PAPER INFO Paper history: Received 11 December 2019 Received in revised form 14 January 2020 Accepted 17 January 2020 Keywords: Broaching Finite Element Method Machining Ti6Al4V Alloy Tungsten Carbide ABSTRACT The aim of this study, is to use finite element simulation to achieve the optimal geometry of a broaching tool that creates the lowest tensile stress at the machined surface of the Ti6Al4V alloy. It plays a major role in reducing production costs and improves the surface integrity of the machined parts. The type and amount of residual stress determined by the thermal and mechanical loads transmitted to the workpiece. In this research, the two-dimensional simulation of the broaching process is done by finite element DEFORM-2D® software for the two end teeth of the tool that perform the cutting operation. In simulating the first tooth, Response Surface Method is used to select the desired controllable parameters of the process such as cutting speed, rake angle, clearance angle, rise per tooth and depth of cut. In order to establish low thermal and high mechanical load in workpiece, multi-objective genetic algorithm employed after perform simulation in the first tooth. In simulating the second tooth, Response Surface Method used to select desired controllable parameters of the process such as rake angle, clearance angle and radius of cutting edge. For the second tooth, a multi-objective genetic algorithm has been used. Ultimately, the geometry of the broaching tool utility has been designed to store the lowest tensile residual stresses in the machined surface for Ti6Al4V alloy. doi: 10.5829/ije.2020.33.04a.17 1. INTRODUCTION 1 Broaching operations are widely used in the machining industry because both roughing and finishing operations are carried out at one step. As a result, the speed of broaching operation is greater than that of machining and milling. The main applications of broaching are to carry out operations on internal or external surfaces of parts or a combination of them. One of the interesting topics of research in simulation of broaching is to achieve the value of residual stress after the process that has a significant effect on the fatigue life of the workpiece. The two end teeth of the tool that perform the cutting operation have the greatest effect on the value of residual stres. This can be controlled by selecting appropriate cutting conditions. On the other hand, Ti6Al4V alloy is a significant engineering material for using in aerospace *Corresponding Author Email: hamirabadi@birjand.ac.ir (H. Amirabadi) applications such as gas turbine engines, due to its high strength and fracture toughness in addition to its low density. It should be noted that the amount and type of residual stress in this alloy for application in turbine blade design, the importance of proper servicing of this piece during its life, high temperatures during operation, and the presence of extreme centrifugal forces, are very important. Considering the working conditions of the workpiece, the design of the broaching tool that causes the tension of the residual pressure stress or the minimum tensile stress is desirable [1]. Despite the importance of the broaching process in the manufacturing industry, relatively little research has been done on it. Here, a short background to the research carried out in the field of broaching has been presented, and studies have shown that so far, research into the design of the Ti6Al4V broaching tool, in which the