Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Broaches
and Broaching
Metal Removal
Cutting-Tool Materials
Metal Removal Methods
Machinability of Metals
14.1 Introduction
The broaching operation is similar to
shaping with multiple teeth and is used
to machine internal and external surfaces such as holes of circular, square,
or irregular shapes, keyways, and teeth
of internal gears. A broach is a long
multitooth cutting tool with successively deeper cuts. Each tooth removes
a predetermined amount of material in
a predetermined location. The total
depth of material removed in one path
is the sum of the depth of cut of each
tooth. Broaching is an important pro-
14.2 Broaching
Tooling is the heart of any broaching
process. The broaching tool is based
on a concept unique to the process -
Pull end
Shank length
Front pilot
Length to
first tooth
Roughing
teeth
Semifinishing
teeth
Cutting teeth
Finishing
teeth
Backoff or
rake angle
Tooth depth
Radius
Gullet or
chip space
(a)
(b)
Keyway Broach: Almost all keyways in machine tools and parts are cut
by a keyway broach - a narrow, flat bar
with cutting teeth spaced along one
surface. Both external and internal
keyways can be cut with these
broaches. Internal keyways usually
require a slotted bushing or horn to fit
the hole, with the keyway broach
pulled through the horn, guided by the
slot.
If a number of parts, all of the same
diameter and keyway size, are to be
machined, an internal keyway broach
can be designed to fit into the hole to
support the cutting teeth. Only the
cutting teeth extend beyond the hole
diameter to cut the keyway. Bushings
or horns are not required.
Burnishers: Burnishers are broaching tools designed to polish rather than
cut a hole. The total change in diameter produced by a burnishing operation may be no more than 0.0005 to
0.001 inch. Burnishing tools, used
when surface finish and accuracy are
critical, are relatively short and are
generally designed as push broaches.
Burnishing buttons sometimes are
included behind the finishing tooth
section of a conventional broaching
tool. The burnishing section may be
added as a special attachment or easily
replaced shell. These replacement
shells are commonly used to reduce
tooling costs when high wear or tool
breakage is expected. They are also
used to improve surface finish.
Shell Broaches: Shell broaches can be
used on the roughing, semi-finishing and
finishing sections of a broach tool. The
principal advantage of a shell broach is
that worn sections can be removed and
re-sharpened or replaced, at far less cost
than a conventional single piece tool.
When shells are used for the finishing
teeth of long broaches, the teeth of the
FIGURE 14.8: A
variety of forms that
can be produced
with an internal
broach.
Keyway
Square
Spline
Triangle
Hexagon
Double D
Special shapes
www.toolingandproduction.com
(a)
(b)
FIGURE 14.9: (a) A surface broach assembly. (Courtesy Detroit Broach & Machine
Co.) (b) A surface broach assembly with indexable carbide inserts. (Courtesy
Ingersoll Cutting Tools)
shell can be ground to far greater accuracy than those of a long conventional
broach tool and the tool can continue to
be used by replacing the shell. Shell
broaches are similar to shell milling
cutters that were discussed in Chapter
12.
(b)
(a)
nents are required. Upon completion
of short runs (1 - 2 years) the machines
can be re-tooled and moved to another
area of the plant without the problem
of what to do with pits in shop floors.
With this type of machine the part sits
on a table that moves up while the
broach is stationary. Stroke lengths
from 30 to 90 inches and capacities
from 5 to 30 tons are the limits for this
machine.
Vertical Internal Pull-up: The
pull-up type, in which the workpiece is
placed below the worktable, was the
first to be introduced. Its principal use
is in broaching round and irregular
shaped holes. Pull-up machines are
now furnished with pulling capacities
of 6 to 50 tons, strokes up to 72 inches,
and broaching speeds of 30 FPM.
Larger machines are available; some
have electro-mechanical drives for
greater broaching speed and higher
productivity.
Vertical Internal Pull-down: The
more sophisticated pull-down machines, in which the work is placed on
top of the table, were developed later
than the pull-up type. These pulldown machines are capable of holding
internal shapes to closer tolerances by
means of locating fixtures on top of the
work table. Machines come with pulling capacities of 2 to 75 tons, 30 to 110
inch strokes, and speeds of up to 80
FPM.
6 Tooling & Production/Chapter 14
(a)
FIGURE 14.12: (a) Two-station internal horizontal
broaching machine. (b) Gear broaching operation.
(Courtesy Detroit Broach & Machine Co.)
roughing and finishing automotive engine blocks, they are used exclusively.
A two station internal horizontal
broaching machine is shown in Figure
14.12a
Horizontal Internal Broaching
Machines: By far the greatest amount
of horizontal internal broaching is
done on hydraulic pull type machines
for which configurations have become
somewhat standardized over the years.
Fully one third of the broaching machines in existence are this type, and of
these nearly one fourth are over twenty
years old. They find their heaviest
application in the production of general industrial equipment but can be
found in nearly every type of industry.
Hydraulically driven horizontal internal machines are built with pulling
capacities ranging from 2 1/2 to 75
(b)
becoming dominant.
A gear broaching operation is shown
in Figure 14.12b.
The older hydraulically driven horizontal surface machines now are produced with capacities up to 40 tons,
strokes up to 180 inches, and normal
cutting speeds of 100 FPM. These
machines, a major factor in the automotive industry for many years, turn
out a great variety of cast iron parts.
They use standard carbide cutting tools
and have some of the highest cutting
speeds used in broaching.
But electro-mechanically driven
horizontal surface machines are taking
over at an ever-increasing rate for
some applications, despite their generally higher cost. Because of their
smooth ram motion and the resultant
improvements in surface finish and
Workpiece
Work holder
Broach
Load manual
or automatic
Work backup
plate
Linked chain
Chips
Unloa
Chip conveyor
(a)
Floor
(b)
FIGURE 14.13: (a) Continuous chain broaching operation. (Courtesy US Broach & Machine Co.) (b) Schematic illustration of a
continuous chain broaching machine.
www.toolingandproduction.com
(a)
(b)
FIGURE 14.14: (a)
Turn-broaching
operation of a
crankshaft. (b) Turnbroach cutter assembly.
(Courtesy Sandvik
Coromant Co.)
14.6 Turn-Broaching
Turn-broaching is an efficient method
for machining steel and nodular cast
iron crankshafts. Special turn-broaching machines are available for linear,
circular and spiral operating methods.
The peripheral type cutter assemblies
are built in segments as shown in
Figure 14.14b.
The turn-broaching systems basically use similar standardized components for roughing and finishing. The
type of machine determines the tool
design: linear, circular or spiral. The
number of segments and roughing inserts in the tool depend on the stock
removal rate required. The finishing
segments are fitted with inserts in adjustable cartridges that can be set to
close tolerances. The segment for
roughing has fixed insert pockets. A
turn-broaching operation of a crankshaft is shown in Figure 14.14a.
Tool segments are computer designed and manufactured for each machine to suit the required form and
tolerance of each crankshaft. The
number of inserts and positions of each
segment are designed to give low cutting forces. The roughing segments
have hardened, fixed insert seats and
big chip pockets. Inserts are tangentially mounted and locked in position
by a center screw. A turn-broach cutter
assembly is shown in Figure 14.14b.
Long tool life results due to the short
engagement of the individual cutting
edges. High machine utilization is
obtained because the finishing cutters
need only be changed once per shift
and the roughing cutters about once
every third shift.
www.toolingandproduction.com