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.
