Abstract: The geometric structure and the manufacturing procedure as well as the corresponding methods for the helical broaching tool are analyzed. In basis of analyze the structure of internal helical ring gear, both the rough cutting section and the finishing cutting section are detailed described on the geometric structure and the work principle. Critical questions i.e. orientation of the grinding wheel for the rake flank sharpen, grinding method for the cutting edge of cutting teeth with backoff requirement, the interference avoidance during the alternative placed cutting teeth grind and the interference avoidance between the finishing cutting teeth grinding are introduced. Reasonable processing routes for helical broaching tool grinding are given, and the optimal step-shape grinding path for finishing cutting section machining is developed. With combine processing route, concise on-line inspections are indicated. The noticeable conditions of on-line inspection that based on both the distance of pin and probe are discussed. With employing the helical broaching tool grinding CAM software that configures with optimal parameter input interface, the machining rough cutting section and the finishing cutting section of the helical broaching as well as the inspection results verify the contributions of the proposed helical broaching tool manufacturing method.

Key words: helical rake flank sharping, interferences avoidance, internal helical broaching tools, machining path planning, on-line inspection, processing route