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Broaching: Types, Fundamentals and Machinery Used

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Introduction

This article takes an in depth look at Broaching.

You will learn more about topics such as:

  • What is Broaching?
  • The machinery used for Broaching
  • Types of Broaches
  • Broaching tool design terms
  • And much more…
Examples of Internal Broaching

Chapter One - What is Broaching?

Broaching is an exacting machining process utilizing a hardened tool with serrated edges to systematically and consistently remove material from a workpiece. This technique employs a tool embedded with teeth of different sizes, systematically shaving away a specified quantity of material during each pass over the workpiece.

In broaching, the action involves the multi-toothed tool either moving while the workpiece stays stationary or vice versa. In certain scenarios, there could be relative rotational movement between the tool and the workpiece. Broaching operations can occur internally through the center of the workpiece or externally along its surface.

External Broach

External or surface broaching incorporates designs like slab, slot, contour, pot, and straddle broaching. On the other hand, internal broaching encompasses approaches such as keyway, concentricity, and cut recut. The specific broaching technique applied depends on the segment of the workpiece being machined or cut.

Chapter Two - What is the Process of Broaching?

Broaching is a widely used machining technique designed to precisely remove material from a workpiece to create specific contours, shapes, and profiles. As a specialized metalworking process within subtractive manufacturing, broaching is recognized for its efficiency in producing intricate internal and external geometries in high-precision industries like automotive, aerospace, and manufacturing. Unlike other machining processes such as milling, turning, or drilling, broaching utilizes purpose-built tools—broaches—with a series of progressively sized cutting teeth to achieve accurate transformations in a single pass.

The primary function of a broach is to press, pull, or push against the workpiece in order to form precise holes, slots, teeth, or patterns. This allows manufacturers to achieve unique internal broaching (e.g., keyways, splines, and polygonal holes) and external broaching (e.g., surfaces, slots, or flat features) that are often unattainable or less efficient when using milling or grinding machines. Broaching stands out for its speed, repeatability, and cost-effectiveness in mass production, as well as the superior surface finish it can deliver.

Broaching Machine

A broaching machine is a straightforward CNC or manually operated industrial machine tool that comprises a broaching tool, a holding fixture, a drive mechanism (usually hydraulic or electromechanical), and a robust support frame. There are two main types of broaching machines: horizontal and vertical. Broaching machines may feature one or more rams—linear actuators that propel the broach—depending on specific applications. For high-volume production, multiple rams allow for simultaneous cutting and return strokes, improving operational efficiency and throughput.

Broaching machines perform operations by either pulling or pushing the broach through or past the stationary or moving workpiece. Power is typically supplied by hydraulic systems, which deliver consistent force and precise control for both internal broaching (creating holes, splines, and keyways) and surface broaching (producing flat or contoured profiles). The machine setup determines the type of broaching—push, pull, surface, or rotary—ensuring precision for every component produced.

Horizontal Broaching Machine

Horizontal broaching machines employ the pull-type broaching method, ideal for internal broaching as well as certain external applications. These machines are commonly used for manufacturing keyways, splines, slots, round holes, and complex internal shapes. The configuration features an elongated bed, a broach pilot to align and guide the broaching tool, and a powerful drive mechanism.

This setup is optimal for machining long broaches and handling heavy workpieces—requirements often found in automotive or heavy equipment manufacturing. However, horizontal broaching machines require significant floor space in the production facility. They deliver high accuracy, repeatability, and allow quick changeovers for multiple part geometries.

Horizontal Broaching Machine

Vertical Broaching Machine

A vertical broaching machine operates by pushing or, in some types, pulling the broaching tool vertically relative to the workpiece. These machines offer great versatility, enabling both internal and surface broaching. With push broaching as the most common operation, vertical broaching machines are suited for mass production of parts requiring accurate slots, holes, and other geometric features.

There are three primary types of vertical broaching machines: push down, pull up, and pull down—each with different capabilities for workpiece handling and broaching force. Pull up machines are especially prevalent in high-production manufacturing for their efficiency and quick loading/unloading of workpieces. Vertical broaching machines may be powered by hydraulic systems or electro-mechanical drives, with hydraulic models offering superior force control and reduced maintenance costs.

Vertical Broaching Machine

Surface Broaching Machine

A surface broaching machine is designed to remove excess material from the flat or contoured surfaces of a workpiece. The broaching tool, typically mounted on a reciprocating ram, traverses the workpiece, cutting multiple profiles or features in a single pass. Surface broaching processes are highly efficient for producing complex contours, slots, or dovetails on components like turbine blades, pistons, and connecting rods. These machines can be configured for horizontal or vertical operation, and duplex broaching machines (with two rams) increase production throughput for batch manufacturing and high-volume runs.

Surface Broaching Machine

Continuous Broaching Machine

In continuous broaching (also known as chain broaching or production broaching), the workpiece moves steadily while the broach remains stationary. This process leverages a conveyor or chain-driven fixture to transport multiple workpieces in sequence through the cutting zone. Continuous broaching is ideal for machining numerous identical parts such as automotive transmission components, small gears, or fasteners, maximizing productivity and part consistency in large-scale manufacturing environments. The process can involve linear, horizontal, or circular movement, depending on the design and intended application.

Continuous Broaching

Rotary Broaching Machine

Rotary broaching—also known as wobble broaching—is a precision method for producing intricate internal and external polygonal shapes. In this technique, often performed on CNC lathes or milling machines, the specialized rotary broach is set at a 1° angle to the workpiece centerline, creating a unique cutting action that produces shapes such as hexagons, squares, serrations, involute splines, spur gears, and even custom forms like numbers and letters, all with tight tolerances and superior surface finishes.

Rotary broaching is highly valued in industries requiring complex non-circular features—such as medical device manufacturing, aerospace, and fastener production—due to its ability to generate finished forms in one quick pass. The rotary broaching tool holder is engineered for stability, feeding the broach into a pre-drilled pilot hole and completing the full shape efficiently. A back taper on the broach minimizes thrust load, extending tool life and protecting the workpiece integrity.

Rotary Broaching

Turn Broaching Machine

Turn broaching machines are utilized for circular, linear, and spiral cutting applications, where a high-quality surface finish and tight dimensional tolerances are essential. The machine uses a specialized tool fitted with multiple cutting inserts to remove material as the workpiece, such as a crankshaft, is rotated between centers. This process supports both roughing and finishing operations—selecting segmental roughing inserts for aggressive material removal and adjustable finishing cartridges for producing precision components with demanding specifications.

Turn broaching is preferred for complex machining operations in automotive engine manufacturing, aerospace turbine construction, and high-precision industrial part production—delivering consistent part geometry, enhanced cycle times, and superior surface integrity.

Turn Broaching Machine

CNC Broaching

Advancements in Computer Numerical Control (CNC) technology have transformed the broaching process, enabling simultaneous integration of both rotary and linear broaching operations with advanced automation and repeatability. CNC broaching machines are equipped with programmable tool paths, indexable insert tools, and custom-designed holders that interface seamlessly with modern CNC lathes and mills. This allows manufacturers to increase productivity, minimize setup time, and achieve consistent results across job lots and custom production runs.

CNC broaching systems support a diverse range of operations—including rotary (wobble), punch, keyway, spline, polygon, and serration broaching—delivering exceptional versatility for producing parts such as transmission gears, medical implants, precision aerospace fasteners, and tooling inserts. By utilizing advanced coolant systems and rigid fixturing, CNC broaching machines enhance surface finish quality and tool life, reducing both cycle times and production costs. This makes CNC broaching an optimal choice for industries demanding high-precision, complex component manufacturing under tight tolerances.

CNC Broaching Machine

In summary, the broaching process encompasses a broad spectrum of techniques, machine types, and applications—ranging from conventional internal and surface broaching to sophisticated CNC and rotary broaching systems. Understanding the capabilities, advantages, and industry applications of each machine type enables manufacturers, engineers, and machinists to make informed choices for part design, process optimization, and high-volume metalworking production. For those evaluating broaching as a solution, consulting with specialized broaching machine manufacturers and tooling suppliers will ensure optimal results in efficiency, cost, and product quality.

Chapter Three – What Are the Leading Broaching Machines?

Broaching demands a high level of precision, durability, and repeatable accuracy to meet the rigorous standards of modern manufacturing. Leading broaching machine manufacturers have continually advanced the industry through innovation in design, automation, and process control. Below are five renowned brands specializing in broaching machines used throughout the United States and Canada. This overview includes prominent models, their core features, and what distinguishes them in the broaching equipment market. Whether you seek solutions for high-volume production, custom component shaping, or precision gear manufacturing, these manufacturers exemplify top performance and reliability in industrial broaching.

Brand: American Broach & Machine Co.

Model: AB-2500H Broaching Machine

Description: American Broach & Machine Co. is a leading name in broaching machine manufacturing, renowned for strong engineering and robust service support. Their AB-2500H model is specifically engineered for high-volume production broaching in automotive, aerospace, and general manufacturing sectors. It offers high-speed operation, computerized process control for repeatability, and flexibility in handling a variety of broach sizes and part profiles. The AB-2500H is celebrated for its reliability, rugged construction, and long-term dimensional accuracy—making it a trusted option for manufacturers seeking consistent, high-quality output with minimal downtime.

Brand: Colonial Tool Group

Model: Colonial G-Series Broaching Machine

Description: Colonial Tool Group is internationally recognized for engineering excellence in broaching equipment and tooling solutions. The Colonial G-Series broaching machine is highly versatile and suitable for both internal broaching (such as splines, keyways, and shapes) and surface broaching applications. Featuring advanced multi-station broach loading, sophisticated CNC controls, and exceptional rigidity, it handles demanding production runs while maintaining high part precision and repeatability. The G-Series is well-suited for manufacturers with diverse or complex broaching requirements, and is praised for both its adaptability and accuracy in intricate metalworking processes.

Brand: Ohio Broach & Machine Co.

Model: OB Series Vertical Broaching Machine

Description: Ohio Broach & Machine Co. designs and builds an extensive range of vertical broaching machines, targeted at industries such as automotive, medical device, and industrial component manufacturing. The OB Series exemplifies efficient vertical broaching, boasting a space-saving design ideal for factory floor layouts, intuitive operator interfaces, and a spectrum of customizable features tailored to precise application needs. Whether producing straight or form broaches, this line delivers consistently high tolerance control, user-friendly operation, and proven durability—providing reliable solutions for businesses seeking optimal broached part quality and manufacturing productivity.

Brand: Broaching Machine Specialties (BMS)

Model: BMS Horizontal Broaching Machine

Description: Broaching Machine Specialties (BMS) is a prominent manufacturer catering to the full range of horizontal broaching machine applications. Their horizontal broaching solutions are ideal for both internal and external profiles, and are equipped with reinforced structures to prevent deflection during heavy-duty cycles. Advanced control systems and highly efficient chip removal subsystems help ensure process safety, precision, and repeatable dimensional accuracy. BMS horizontal broaching machines excel in versatility, capable of processing diverse part geometries and materials commonly found in industries such as transportation, defense, and oilfield equipment manufacturing.

Brand: Nachi America Inc.

Model: Nachi Gear Cutting Broach Machine

Description: Nachi America Inc. specializes in advanced gear broaching machines uniquely designed for precision gear manufacturing. These machines are equipped with high-speed, high-torque drives and cutting-edge tooling solutions that enable the efficient machining of complex gear tooth profiles and splines. Nachi’s solutions are renowned for their outstanding tolerance control, fast cycle times, automation integration options, and innovative lubrication systems that enhance tool life. Industries including automotive transmission manufacturing, industrial gear production, and heavy equipment assembly rely on Nachi for consistent, precise, and cost-effective gear broaching operations.

It is essential to note that broaching machine models, specifications, and features frequently evolve due to continual advances in manufacturing technology. For up-to-date information about machine configurations, technical support, and service offerings in the U.S. and Canada, contact these manufacturers directly or consult their product catalogs. Selecting the right broaching machine for your operation involves careful consideration of application needs, production volume, component material, and desired tolerances to ensure optimal performance and cost efficiency.

How to Choose the Best Broaching Machine for Your Application

Choosing the ideal broaching machine involves evaluating production requirements, the types of parts and materials you work with, and the necessary automation features for maximum throughput and precision. Consider factors such as:

  • Broach Type: Internal vs. external profiles, surface, rotary, or linear broaching.
  • Capacity & Tonnage: Machine tonnage and stroke length required for your broaching process.
  • Automation & Integration: Compatibility with robotic loading, smart sensors, and factory automation systems.
  • Precision Requirements: Tolerance levels, repeatability, and quality control systems.
  • After-Sales Support: Access to technical support, spare parts, and maintenance services.
  • Industry Application: Specialized features for sectors such as automotive, aerospace, medical, and tool & die manufacturing.

Investing in the right broaching solution can significantly enhance productivity, reduce unit costs, and improve the quality of your finished parts, cementing your competitive advantage in precision manufacturing.

Leading Manufacturers and Suppliers

    Mouse Over Company Names to see their previews

    Chapter Four - What are the different types of broaching?

    The process of broaching produces parts with exceptional surface finishes and dimensional accuracy. A broaching tool has rough, semi-finish, and finish cutting teeth capable of finishing the machining of a rough surface in one stroke.

    For internal broaching, the tool can either be pulled or pushed through the workpiece, or the workpiece can be moved across the stationary tool. This process requires a starting hole to insert the broach into the workpiece.

    A broach is a cutting tool with multiple teeth that functions similarly to a chisel, but with a flat-ended sharp edge. In some instances, the broach teeth are arranged diagonally to perform shearing cuts, resulting in sliding or skewing deformations.

    The Broach

    A broach is a cutting tool featuring multiple rows of teeth, each progressively larger than the last. This design allows a broach to create both simple and intricate cuts quickly and with precision. Throughout the broaching process, each pass of the broach removes a shallow layer of material along the length of the workpiece.

    Linear Broach

    Linear Broaching

    Among the different broaching techniques, linear broaching is the most widely used. In this process, the tool moves in a straight line across the surface of the workpiece, making cuts as it progresses to the end. The diagram illustrates an example of linear broaching.

    Linear Broaching

    Pull Broaching

    In pull broaching, the broach is drawn through a stationary workpiece. This method uses long broaches equipped with a specialized head, and the tension generated during the pulling action enhances the effectiveness of the broach. While pull broaching is primarily used for internal or interior broaching, it can also be applied to surface broaching. These broaches feature numerous teeth, allowing for extended cutting operations.

    Pull broaching can be performed vertically (up or down) or horizontally, either through or across the workpiece. It is commonly used to achieve flat surfaces on automobile cylinder blocks and heads.

    A Pull Broaching Tool

    Push Broaching

    A push broaching tool is shorter to withstand the compressive forces exerted during the broaching process. It typically has fewer teeth, which are more prone to bending or breaking under these forces. Push broaching is suited for creating shorter cuts, making it ideal for producing smaller parts.

    Push broaching tools are often used for surface broaching, and when employed for this purpose, they are specifically referred to as surface broaching tools.

    A Push Broach

    Pot Broaching

    Pot broaching is used with cylindrical workpieces and has a pot shaped tool holder. In pot broaching, the tool remains stationary as the workpiece is pushed or pulled through it. Pot broaching produces a cut inverse that of interior broaching and is used with other machining or independently. The tool for pot broaching is extremely complex and requires a special fixture; this makes pot broaching a seldomly used process.

    Pot Broaching Tools

    Spline Broaching

    Spline broaching, also referred to as round broaching, is used to create round, plain, or irregular splines and spiral tooth forms. It is commonly employed to manufacture shafts, gears, and other mechanical components that mesh together. This prevalent form of broaching involves using a broach to produce a series of ridges or teeth around the circumference of a pre-cut hole. Spline broaching is an efficient method for creating serrated, straight, and involute splines.

    In the automotive industry, spline broaching is essential for producing transmission and driveshaft components. The grooves formed in the spline enable effective torque transfer by interlocking separate parts.

    Blind Broaching

    Blind broaching refers to the broaching process where the tool does not pass completely through the part, meaning the tool machines into a blind cavity. The process of blind broaching is used on parts that are designed to not have a pass through. In the case of keyways, they can be designed to be a blind broaching when the tool stops in the middle of the bore.

    A Blind Spline Broaching

    Internal Broaching

    With internal broaching, material is removed from the interior or internal surface of the workpiece; this is known as hole broaching. Prior to beginning the internal broaching process, a starter hole is drilled into the workpiece; this is referred to as blank prepping. Internal broaching is used to enlarge, widen, and resize a hole.

    The internal broaching tool features teeth that progressively increase in size, ensuring a high-quality finish on the workpiece. Internal broaching is typically performed using automated machinery, such as CNC machines, which offer rapid and efficient hole production. This method can be executed using either the push or pull broaching process. Internal broaches are categorized into types such as round and spline.

    Internal Broaching

    External Broaching

    External broaching, also known as surface broaching, involves removing material from the exterior of the workpiece. Similar to internal broaching tools, external broaching tools feature teeth that gradually increase in size. This process employs a guided ram with a broach holding fixture, with the cutting force transmitted to the ram along the length of the broach.

    External broaches are used for creating flat and contoured surfaces. In flat surface broaching, the tool moves across the workpiece to achieve a specific surface finish. Form surface broaching, on the other hand, is used to create various contours and shapes, including serrated edges, angular splines, gear profiles, fir tree slots, compressor slots, and keyways.

    Common External Broaching Forms

    Chapter Five - What are the key terms in broaching tool design?

    The effectiveness of broaching largely depends on the design of the broaching tool. A well-designed tool minimizes issues such as drift, deflection, and breakage while enhancing cutting efficiency. Designing broach tools is a specialized field within manufacturing engineering that encompasses the analysis, planning, design, production, and application of these tools.

    A crucial aspect of a broach is the "rise per tooth," which indicates the amount of material each tooth removes with each pass. Broaches are typically divided into sections for roughing, semi-finishing, and finishing, and can be used for various types of shaping, including internal, external, surface, or exterior broaching.

    Surface Broach Designs

    Slab

    Slab broaching is one of the most straightforward broaching methods, used primarily to cut flat surfaces. This process is often employed to create square ends, which can then serve as a foundation for subsequent broaching operations.

    Slot

    Slot broaching is used to create slots of varying depths and widths in the workpiece. It is often preferred in high-production environments due to its efficiency and cost-effectiveness compared to milling.

    Nibbling

    Nibbling or egress broaches feature narrow roughing teeth set at an angle to the centerline, along with full-width teeth designed for semi-finishing cuts.

    Contour

    Contour broaches are used to cut concave, convex, cam-shaped, and irregular surfaces with high precision and exceptional tolerances.

    Pine Tree

    Dovetail or pine tree broaches are used to create forms in compressor wheels for securing blades within a turbine disc. This type of broaching typically requires multiple passes due to the complexity of the workpiece and the detailed nature of the forms.

    Pine Tree Broach

    Pot

    Pot broaches are designed to cut external shapes like spur gears, splines, slots, and other tooth profiles. Their design enables the creation of these forms in a single pass. Pot broaching has largely replaced hobbing for manufacturing external gears due to its efficiency.

    Straddle

    Straddle broaching employs two slab broaches to simultaneously cut identical parallel surfaces on opposite sides of the workpiece in a single pass. This method ensures a precise dimensional relationship between the two surfaces.

    Straddle Broach

    Internal Broaching

    Internal broaching comes in two main types: rotary and vertical. Both are designed to enlarge holes within a workpiece. All internal broaching processes require a preliminary starter hole, known as blank prepping. Vertical broaching can be performed using either the push or pull method, while rotary broaching is ideal for creating asymmetrical holes in a single pass.

    Internal broaches are mounted on their shank and secured with a set screw clamp that features a whistle notch for stability.

    Shell Broaching

    Shell broaches are versatile tools used for semi-finishing, roughing, and finishing operations. Sections of a shell broach can be replaced or sharpened as needed. For finishing tasks, shell broaches offer superior accuracy compared to longer broach tools.

    Shell Broaching Tool

    Round Hole Broaching

    Round hole broaching is one of the most straightforward forms of internal broaching. This tool features a series of teeth arranged around its circumference, specifically designed to cut the outer edge of the hole. When working with soft, ductile metals, round hole broaches may require a chipbreaker to manage chip removal.

    Keyway Broaching

    The keyway broach is a widely used type of internal broach. It is designed to cut a slot within the bore of the workpiece and is guided by a fixture known as a horn, which ensures precise positioning of the keyway.

    Example of a Keyway Broaching

    Internal Gear Broaching

    An internal gear broach meticulously removes material from the internal surface of the workpiece to create a gear profile.

    Gun Barrel Broaching

    A gun barrel broach is exceptionally long, designed to traverse the entire length of the barrel. It features very fine teeth, as the grooves in the barrel are only a few thousandths of an inch deep. The broach is pulled through the barrel while rotating, creating the spiral rifling pattern.

    Gun Barrel Bore

    Concentric Broaching

    For spline broaching, maintaining concentricity of the pitch diameter is crucial. A concentric broach is designed as a comprehensive finishing tool, featuring both round and spline teeth that refine the diameter and spline profile.

    Cut and Recut Broaching

    Broaching splines in thin-walled components can be challenging because the walls may expand during the broaching process and then return to their original shape. To address this, a cut and recut broach includes a relief area behind it to avoid wall deformation. The initial tool performs the spline cut, and a subsequent tool refines the cut area.

    Square Broaching

    Square broaches are employed to modify, enlarge, and finalize irregular openings. They are designed to convert a round hole into a square shape using a rotary broach holder that positions the broach so only one corner is cut at a time. These broaches create square holes for accommodating square shafts, and the holes can be either blind or through cuts.

    Broaching Terminology

    Broaching tools are used to remove material from a workpiece using a multi-toothed cutting instrument, where each row of teeth is progressively higher than the previous one. Broaching tools generally have three primary sections: roughing, semi-finishing, and finishing.

    Terminology for a Pull Type of Broaching Tool

    Broaching Tool Terminology

    Pull End

    The pull end attaches the broach to the pulling mechanism on the broaching machine.

    Shank

    The shank refers to the portion from the bridge to the root diameter, which is held and drawn into the machine. The length from the pull end to the root diameter is termed as the shank length.

    Front Pilot

    The front pilot, as the name suggests, ensures the broach is centered within the hole being broached.

    Roughing Teeth

    Located at the front of the broach, these teeth make initial contact with the workpiece.

    Semi-Finishing Teeth

    Following the roughing teeth, the semi-finishing teeth are smaller and remove less material from the workpiece.

    Finishing Teeth

    The finishing teeth are uniform in size and are responsible for refining the workpiece to the final dimensions and shape required.

    Rear Pilot

    The rear pilot stabilizes and aligns the broach during operation.

    Follower End

    The follower end serves a function similar to the rear pilot, providing support to the tool's components.

    Push Type Broaching Tool

    The push type broaching tool is designed to be shorter and endures compressive forces as it advances through the workpiece. The teeth of a push broaching tool are smaller and less prone to breaking or bending compared to those of a pull-type broaching tool.

    The components of a push broaching tool mirror those of the pull broaching tool.

    Terminology for an External Broaching Tool

    External or surface broaching involves removing material from the outer surface of the workpiece. Similar to pull-type and push-type broaches, the teeth of external broaching tools increase progressively.

    External Broaching - Serration, Rough Spline, Hexagon, Torque

    Land

    The land is the area at the base of the teeth, providing support to the cutting edge.

    Rake

    During the broaching process, the rake helps direct the chips created by the cutting action.

    Pitch

    The pitch refers to the spacing between adjacent cutting edges on the broach teeth.

    Clearance Angle

    The clearance angle is the angle formed between the land and the horizontal axis, designed to minimize friction between the teeth and the workpiece. This ensures that only the cutting edges engage with the workpiece.

    Depth

    The depth denotes the vertical measurement of each tooth.

    Gullet Radius

    The gullet radius is the curved space between two teeth, allowing the chips to flow out after being formed.

    Chipbreaker

    Chipbreakers are notched features designed to prevent chip buildup and facilitate chip removal. They are ground into the roughing and semi-finishing teeth parallel to the tool's axis, arranged in a staggered pattern to follow the cutting teeth. Chipbreakers are crucial in round broaching tools for preventing the formation of ring-shaped chips.

    Side Relief

    When broaching slots, the tool is confined by the slot and must carry chips along its length. A side relief angle is applied to the teeth to reduce wear from rubbing against the slot walls and to maintain a small cutting edge area.

    Chapter Six - What are the common uses for broaching?

    While broaching is an age-old machining technique, it remains a crucial element in modern industrial processes. Today, broaching is integral to the manufacturing of precision components such as nuts, bolts, and gears used in aerospace and automotive sectors, thanks to its ability to produce highly accurate parts with tight tolerances.

    Broaching is predominantly utilized for high-volume production where precise, repetitive, and intricate cuts are required. It accommodates a diverse range of materials, with metals ideally suited for broaching typically having a Rockwell C hardness rating between 26 and 28.

    Different broaching techniques are tailored to meet specific application needs. Broaching excels in applications that demand parallel and multiple surface cuts, rapid processing, automation, large-scale production, and working with tough materials.

    Broaching can replace various metal shaping processes, offering time efficiency and reduced tool usage. It is effective on a broad spectrum of materials, including soft metals like aluminum, copper alloys, brass, some plastics, wood, and midrange steel. Although broaching is possible for very hard materials like titanium, the process tends to quickly dull the broaching tool due to the metal's hardness.

    Examples of components produced using broaching for automotive transmissions include:

    A gear used for positioning clutch plates:

    Transmission Gear

    Here is an example of a transmission component manufactured using push broaching, where the splines and teeth are cut in a single pass.

    Transmission Part Produced Using Push Broaching

    The component shown below exemplifies pot broaching for a drive mechanism, where meticulous control is essential to achieve accurate tolerances.

    Pot Broaching

    Below is an example of internal broaching used for creating transmission gears in various sizes and involute splines.

    Internal Broaching of Transmission Gears

    While broaching is versatile and effective for various machining tasks, several considerations must be taken into account before selecting this process.

    Firstly, the workpiece surface needs to be aligned parallel to the movement of the broaching tool. Any surface imperfections, obstructions, or irregularities can hinder the broaching process, as it relies on a continuous, unidirectional cut.

    Broaching is typically not suitable for creating multiple contours, curves, or angles across different planes in a single pass, with the exception of specialized applications like helical gear teeth.

    Additionally, the material being broached should be capable of withstanding the forces exerted during the process. Components with thin walls or delicate cross-sections may not be suitable for broaching due to their potential fragility.

    Broaching Materials

    Broaching works best with materials that are softer, more ductile, and flexible. Although some high tensile strength steels and other hard metals can be broached, the suitability of a material depends on the equipment, tools, and methods used in the process.

    Steel is the most frequently broached material due to its versatility across various applications. The specific grade of steel plays a significant role in determining its suitability for broaching.

    Materials Used in Broaching

    Materials Used in Broaching

    Here is a brief overview of materials frequently used in broaching. Various types of plastics, copper alloys, and other materials are also processed using this technique. Broaching tools can be specially designed and engineered to accommodate the specific requirements of different materials, ensuring they meet the demands of any application.

    • Brass
    • Aluminum
    • Titanium
    • Stainless Steel
    • Alloy Steel
    • 12L14 Cold Finish Carbon Steel
    • Plastic
    • Cast Iron

    Conclusion

    • Broaching is a machining process where a sharp hardened toothed tool removes material from a workpiece in a consistent, continuous, and accurate way.
    • The broaching process varies according to the portion of the workpiece that will be broached or cut.
    • The process of broaching produces parts with exceptional surface finishes and dimensional accuracy.
    • Though broaching is an ancient form of machining, it has become a valuable part of many industrial operations.
    • The key to broaching is the design of the broaching tool. A properly designed tool can lessen the possibility of drift, deflection, and breakage as well as provide efficiency during the cutting process.

    Leading Manufacturers and Suppliers

      Mouse Over Company Names to see their previews

      Table of Contents

      Chapter One - What is Broaching?

      Chapter Two - The Process of Broaching

      Chapter Three - Leading Broaching Machines

      Chapter Four - Types of Broaching

      Chapter Five - Broaching Tool Design Terms

      Chapter Six - Uses for Broaching

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      What is CNC?

      What is CNC

      The CNC process, computer numerical control, is a method of manufacturing where programmed software directs the operation of factory tools and machinery. It is designed to manage a wide range of complex machines from grinders and lathes to mills and routers...

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