Broaching

Broaching is the process of removing metal with a tool which has teeth arranged in a row. Each tooth is successively higher than the previous tooth and removes more material. In broaching, one stroke or cycle of the machine produces a finished part.
Broaching is used to produce both internal and external features. Production rates are high and tolerances of +/.0005 are possible.

Precise process for mass-production of complex geometry parts (complicated hole-shapes) Process character: High MRR, Very good surface, dimension control, Expensive

Broaching machine

Broaching tools

Complex hole shapes cut by broaching

Examples of parts made one Planer and by Broaching

Fig : Typical parts that can be made on a planer.

Fig : (a) Typical parts that can be made by internal broaching. (b) Parts made by surface broaching. Heavy lines indicate broached surfaces.

Broaches

Fig : (a) Cutting action of a broach, showing various features. (b) Terminology for a branch.

Chipbreakers and a Broaching Machine

Fig : Chipbreaker features on (a) a flat broach and (b) a round broach. (c) Vertical broaching machine.

Internal Broach and Turn Broach

Fig : Terminology for a pull-type internal broach used for enlarging long holes.

Fig : Turn broaching of a crankshaft. The crankshaft rotates while the broaches pass tangentially across the crankshafts bearing surfaces.

Broaching Internal Splines

Fig : Broaching in internal splines.

Major Parameters of broaching machine

The major parameters of broaching machines are the pulling capacity of the ram, which may reach 1 meganewton, and the stroke length of the ram, which may reach 2 m. The cutting speed of general-purpose machines varies from 15 to 20 m/min and in special machines may reach 90 m/min. The cutting speed in continuous machines ranges from 1.5 to 15 m/min. The drive in these machines is usually hydraulic, but high-speed machines use electromechanical drive. Broaching machines are used in mass production and in producing items in large lots. They provide high precision (classes 12) and low surface roughness on the worked surfaces

Methods of Operation
Pull broaching - Broach is pulled through or across stationary work.
Push broaching - Broach is pushed through or across work. Surface broaching - Either the work or the broach moves across the other. Continuous broaching - The work is moved continuously against stationary broaches. The path of the movement may be straight or circular.

Machines
Vertical single and double slide - Table moves part into position for
broaching, part is broached and the table retracts for unloading. --Vertical push broaching - Used for internal features such as holes, rounds, or slots. --Vertical pull down. ->Tool is suspended above work. ->Lowered into pull mechanism in the base of the machine. Advantages:1. Part positioning is easy. 2. Large parts are handled efficiently.

 Vertical single and double slide

Horizontal
--Versatile machine capable of producing internal and external features:-

-> Key-ways -> Gear teeth -> Riffling

High cutting speeds in the range of 10-40ft/min with return speeds of 110 ft/min. MRR of in per stroke is possible.

Rotary
--Parts are mounted to a rotating table and are moved to different stations for different operations:-->Primarily used on small parts. -->Typical operations include:1. Slotting 2. Holes 3. Key-ways

Chip Formation
Chip formation involves three basic requirements:
The cutting tool must be harder than the part material. There must be interference between the tool and the part as designated by the feed rate and cut per tooth. There must be a relative motion or cutting velocity between the tool and work piece with sufficient force to overcome the resistance of the part material.

Chip Formation
As long as these three conditions exist, the portion of the material being machined that interferes with the free passage of the tool will be displaced to create a chip.
Many combinations exist that may fulfill such requirements. Variations in tool material and tool geometry, feed and depth of cut, cutting velocity, and part material have an effect not only upon the formation of the chip, but also upon cutting force, cutting horsepower, cutting temperatures, tool wear and tool life, dimensional stability, and the quality of the newly created surface.

Plastic Deformation
Originally, it was thought that chips formed in metal cutting were created in much the same way that wood chips are formed when split by an axe. This may be partially true for brittle materials such as cast iron, but it does not hold true for the majority of metals. The process by which chips are formed with metal-cutting tools is called plastic deformation, and was first described by Rosenhain at the Stratsfordshire Iron and Steel Institute in 1906.

How and Where Heat is Generated

The force or energy that is put into the tool creates movement in a group of metal atoms in the work piece. This group is a finite number of atoms which are forced to change their positions in relationship to each other. As the atoms in the metal ahead of the tool are disturbed, the friction involved in their sliding over one another is thought to be responsible for 60% or more of the total heat generated.

This internal friction, and the heat it generates, can be compared to the friction and heat caused by bending a paper clip back and forth until it breaks. As the tool continues to push through the work piece, a chip eventually slides up the cutting face of the tool. This sliding creates an external friction which again releases heat. This external friction accounts for about 30% of the total heat generated. The third area of heat generation is on the land or flank of the tool. This area accounts for about 10% of the heat generated. This is assuming that the tools are sharp and made correctly as far as clearance angles and face angles are concerned. As the tool wears, the above percentages will vary, especially when there is excess wear on the land, or if the clearance angle is insufficient for the material or the part configuration. This contact zone will actually increase as the part continues to close in after the cut resulting in extremely high pressures on the land area of the tool.

Advantages & Disadvantages

Advantages:Rough to finish in one pass. Production rates are high. Cutting time is quick. Rapid load and unload of parts. External and internal features. Any form that can be produced on a broaching tool can be produced. Production tolerances are excellent. Surface finishes are equal to milling. Operator skill is low.

Disadvantages:Tooling cost can be high. In some cases--not suited for low production rates. Parts to be broached must be strong enough to withstand the forces of the process. Surface to be broached must be accessible.

Submitted By:Simran Preet Singh ME-B {4th} 90111124403