BROACHING

INTRODUCTION :

Broaching is a machining process that uses a toothed tool, called a broach, to remove material.

Broaching is an unusual machining process because it has the feed built into the tool.

A broach is effectively a collection of single point cutting tools arrayed in sequence, cutting one after the other; its cut is analogous to multiple passes of a shaper. A Broach is a special multipoint cutting tool. Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool.

The broach contains three distinct sections:

One for roughing, Another for semi-finishing, and The last one for finishing.

Roughing broach

Semi Finishing Broach

Finishing Broach

Broaches

Broaching speeds vary from 20 to 120 surface feet per minute (SFPM). This results in a complete cycle time of 5 to 30 seconds. Most of the time is consumed by the return stroke, broach handling, and work piece loading and unloading.

CLASSIFICATION
OF BROACHING

MACHINES :

According to nature and direction of cutting

Horizontal Broaching Machine Vertical Broaching Machine Continuous Broaching Machine

According to the purpose

Internal Broaching Machine External Broaching Machine

CLASSIFICATION OF BROACHING MACHINE :

According to the construction of the broach tool

Solid Broaching Machine Inserted tooth Broaching Machine Progressive Cut Broaching Machine Built-up Broaching Machine

According to the function

Keyway Broaching Machine Burnishing Broaching Machine Splining Broaching Machine Round-Hole Broaching Machine Surface Broaching Machine

CLASSIFICATION
OF BROACHING

MACHINE :

According to the number of main slides

Single Broaching Machine Double Broaching Machine Multiple slides Broaching Machine

According to the motion of Broach tool

Straight-line Broaching Machine Stationery Broach tool Broaching Machine

TYPES OF BROACHING :
There are many types of broaching methods being used, but mainly there are two main types of broaching. They are

Surface Broaching Internal Broaching

SURFACE BROACHING :

Surface broaching is very simple as either the workpiece is moved against a stationary surface broach, or the workpiece is held stationary while the broach is moved against it.

Surface Broaches :
Slab Broach : The slab broach is the simplest surface broach. It is a general purpose tool for cutting flat surfaces. Slot broaches are for cutting slots of various dimensions at high production rates. Slot broaching is much quicker than milling when more than one slot needs to be machined, because multiple broaches can be run through the part at the same time on the same broaching machine.

Contour broaches are designed to cut concave, convex, cam-contoured, and irregular shaped surfaces. Pot broaches are cut the inverse of an internal broach; they cut the outside diameter of a cylindrical workpiece. The pot is designed to hold multiple broaching tools concentrically over its entire length. The broach is held stationary while the workpiece is pushed or pulled through it. Straddle broaches use two slab broaches to cut parallel surfaces on opposite sides of a workpiece in one pass. This type of broaching holds closer tolerances than if the two cuts were done independently. It is named after the fact that the broaches "straddle" the workpiece on multiple sides.

BROACH TOOL :

BROACHES

INTERNAL BROACHING :

Internal broaching is the process by clamping the workpiece into a special holding fixture, called a workholder, which mounts in the broaching machine. The broaching machine elevator, which is the part of the machine that moves the broach above the workholder, then lowers the broach through the workpiece. Once through, the broaching machine's puller (a hook), grabs the pilot of the broach. The elevator then releases the top of the pilot and the puller pulls the broach through the workpiece completely. The workpiece is then removed from the machine and the broach is raised back up to reengage with the elevator. The broach usually only moves linearly, but sometimes it is also rotated to create a spiral spline or gun-barrel rifling.

INTERNAL BROACHES :
Solid broaches are the most common type; they are made from one solid piece of material. For broaches that wear out quickly shell broaches are used; these broaches are similar to a solid broach, except there is a hole through the center where it mounts on an arbor. Shell broaches cost more initially, but save cost overall if the broach must be replaced often because the pilots are on the mandrel and do not have to be reproduced with each replacement.

INTERNAL BROACHES :
Modular broaches are commonly used for large internal broaching applications. They are similar to shell broaches in that they are a multi-piece construction. This design is used because it is cheaper to build and resharpen and is more flexible than a solid design. A common type of internal broach is the keyway broach (C & D). It uses a special fixture called a horn to support the broach and properly locate the part with relations to the broach.

INTERNAL BROACHES :
A concentricity broach is a special type of spline cutting broach which cuts both the minor diameter and the spline form to ensure precise concentricity.[8] The cut-and-recut broach is used to cut thin-walled workpieces. Thin-walled workpieces have a tendency to expand during cutting and then shrink afterward. This broach overcomes that problem by first broaching with the standard roughing teeth, followed by a "breathing" section, which serves as a pilot as the workpiece shrinks. The teeth after the "breathing" section then include roughing, semifinishing, and finishing

KINDS OF BROACHES :

BROACHING SPECIFICATIONS :
Broaching speeds vary from 20 to 120 surface feed per minute (SFPM). This results in a complete cycle time of 5 to 30 seconds. Most of the time is consumed by the return stroke, broach handling, and workpiece loading and unloading. Common internal holes can range from 0.125 to 6 in (3.2 to 150 mm) in diameter but it is possible to achieve a range of 0.05 to 13 in (1.3 to 330 mm).

BROACHING SPECIFICATIONS :
Surface broaches' range is usually 0.075 to 10 in (1.9 to 250 mm), although the feasible range is 0.02 to 20 in (0.51 to 510 mm). Tolerances are usually 0.002 in (0.05 mm), but in precise applications a tolerance of 0.0005 in (0.01 mm) can be held. Surface finishes are usually between 16 and 63 microinches (in), but can range from 8 to 125 in.[10] There may be minimal burrs on the exit side of the cut.

Broaching samples :

SUITABLE MATERIALS :
Broaching works best on softer materials, such as brass, bronze, copper alloys, aluminium, graphite, hard rubbers, wood, composites, plastic. However, it still has a good machinability rating on mild steels and free machining steels. When broaching, the machinability rating is closely related to the hardness of the material. For steels the ideal hardness range is between 16 and 24 Rockwell c(HRC); a hardness greater than HRC 35 will dull the broach quickly. Broaching is more difficult on harder materials stainless steel and titanium but is still possible.

BROACHING MACHINES :

Horizontal Broaching Machine :

In this type, the broach moves in horizontal direction relatively with the workpiece. Otherwise, the workpiece is set in horizontal motion relative to the broach. Both internal and surface broaching can be performed using HBM.

HORIZONTAL BROACHING MACHINE :

VERTICAL BROACHING MACHINE :

The working of vertical broaching machine is similar to that of horizontal broaching machine. Here, either the broach is set in vertical motion instead of horizontal motion. It is further classifies into 3 types, namely

Pull up type Pull down type Push down type

VERTICAL BROACHING MACHINE :

CONTINUOUS BROACHING MACHINE :

Continuous type :

This type is used for mass production of smaller parts. The broaches are fitted into a belt driven by a set of pulleys, such that the workpiece is held normal to the broach.

ROTARY BROACHING MACHINE

Rotary type :

This machine has a rotary table and vertical column. The broach is fitted horizontally above the table.
A series of fixtures are mounted on the rotay table for locating and holding work pieces. They move past the stationarey broaches. Rotary broaching machines are limited to small parts. They are used for squaring distributor shaft, slotting and the facing of smaller parts.

QUERIERS

THANK YOU!!!
Prepared By : MIHIR KUMAR. K.BHATT [email protected]