About Broaching Job Shops and Broaching Services Including:
Gear Hobbing, Keyseater, Rotary
Broaching, Spline
Cutting, Spline
Shafts & Vertical
Broaching.
Broaching services offer easy methods of precision
machining that can be performed on an external surface (round, flat or
contoured) or the internal part of a shape or form. Virtually any material,
from ferrous
and nonferrous metals
to plastic
materials
and wood, can be cut through broaching. Various broaching methods are
performed in broaching job shops to cut internal splines, gears and sprockets,
as well as keyways, slots and serrations on the surface of a workpiece.
During the process, machines such as automatic lathes, CNC
Swiss lathes and rotary transfer machines are used to push
or pull a broaching tool with cutting teeth through or over a workpiece.
The only limit to the process is the length and width of the part that
is being machined.
The most common form of broaching services is done using hydraulic driven
broaching machines. This process is commonly known as "pull broaching," with
the broach cutting tool "pulled" through the part in a single
pass. The second most common type of broaching services used is "push" type
broaching. Broaching job shops most often utilize this service on short
run jobs using a hydraulic press, or more commonly, a hand operated "arbor
press." Broaching job shops can also perform broaching on a lathe
and rotary broaching. While broaching on a lathe, the broach tool must
be held at a 1° angle to the workpiece. The cutting face of the broach
should be positioned as close to the centerline of the workpiece as possible.
The entire process takes place in a matter of seconds. Rotary broaching
is similar, except that the tool and part are stationary while the broach
holder spins on a spindle, rather than the reverse on an automatic lathe.
As the broach tool and the part come into contact, the tool moves in a "wobble" motion;
thus, another name for this process is wobble broaching.
Broach tools are the parts that actually cut through the workpiece. These
tools are held in place by broach holders and come in many sizes, materials
and varieties based on the desired cut. The two main types of broach tools
are internal broaches and external broaches. Internal broaches are pushed
through the part, while external broaches pass over the workpiece to remove
material on the surface. Broach tools have teeth in varying sizes and shapes
that are arranged so that each tooth will cut a chip of precise thickness.
Chips are accumulated in spaces between the broach teeth. The size and
spacing of the broach teeth is determined by the length of the part being
broached.
Broaching has many advantages, including high productivity, economical
operation, accurate cuts over large runs, close tolerances, versatility
and smooth finishes. Some points are important to remember while broaching.
As chips accumulate in the hole, they must be cleared periodically so that
they do not cause damage to the broach tool. Also, drill the hole as deep
as possible to allow room for the chips to accumulate. Sometimes a pressure
relief vent on the broach tool is necessary when broaching a tight hole
if air, oil and coolant cannot escape. If enough hydraulic pressure is
generated, the broach will be pushed back and could cause damage to the
machine. A ventilation hole on the tool prevents this.
Types of Broaching Job Shops
- is the process of using a broaching machine to cut gear teeth.
- involves using a broach tool to make precise
cuts to a preexisting hole on the inside of a workpiece.
- are machines that make the keyway holes inside locking mechanisms.
- , also known as wobble broaching, is a popular broaching
method that has been used for years on automatic lathes, and is now gaining
popularity on rotary transfer machines and CNC Swiss lathes.
- is a broaching process that cuts grooves into the length of a spline shaft.
- have grooves created by broaching machines.
- involves using a broach tool to precisely cut the surface
of a workpiece.
- are cutting tools with successively larger teeth.
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Broaching Job Shops Terms
- A metal cutting tool with a series of
cutting teeth.
- The space between the teeth on a broach that accumulates
chips during the cutting operation.
- A broach that cuts along the external surface
of a workpiece.
- The angle of the cutting edge of a broach tooth.
- Teeth for finishing a surface that are arranged
at a constant size at the end of a broach.
- Another name for "chip space."
- Another name for a tooth's "face angle."
- A broach that is pulled or pushed through a hole
in the workpiece in order to bring the hole to a desired size and shape.
- The length of a broach tool.
- The measurement from the cutting edge of one tooth to the
same point on the next.
- A type of broach that is pulled through or over the
surface of the workpiece during an operation.
- A type of broach that is pushed through or over the
surface of the workpiece during an operation.
- The teeth that cut first in a broaching operation,
with heavier cuts than semi-finishing teeth.
- A broach with a circular section.
- On surface broaches, the angle between the cutting
edge of a shear tool and the line perpendicular to the broach axis or
line of travel.
- A type of tooth used on surface and external
broaches, positioned so that it does not make a right angle with the
direction of broach motion.
- An external broach that is used to cut a flat
or contoured surface.
- From the root to the cutting edge, the height of
the tooth or broach gullet. |