MANUFACTURING TECHNOLOGY
UNIT V
Machine Tools
Manufacturing Technology
BASIC PRINCIPLES OF BROACHING
Broaching is a machining process for removal of a layer of material of
desired width and depth usually in one stroke by a slender rod or bar type
cutter having a series of cutting edges with gradually increased protrusion
as indicated in Fig.a. In shaping, attaining full depth requires a number of
strokes to remove the material in thin layers step by step by gradually
in-feeding the single point tool (Fig.b).. Whereas, broaching enables
remove the whole material in one stroke only by the gradually rising teeth
of the cutter called broach. The amount of tooth rise between the
successive teeth of the broach is equivalent to the in feed given in shaping.
Manufacturing Technology
Basic principles of Broaching
Manufacturing Technology
Basic principles of Broaching
Finishing hole by broaching
Manufacturing Technology
Basic principles of Broaching
Continuous broaching.
Manufacturing Technology
Nomenclature of broaching tool
Both pull and push type broaches are made in the form of slender rods or bars of
varying section having along its length one or more rows of cutting teeth with
increasing height (and width occasionally). Push type broaches are subjected to
compressive load and hence are made shorter in length to avoid buckling.
The general configuration of pull type broaches, which are widely used for
enlarging and finishing preformed holes, is schematically shown in Fig.
Manufacturing Technology
Nomenclature of broaching tool
Pull end for engaging the broach in the machine
Neck of shorter diameter and length, where the broach is allowed to fail, if
at all, under overloading
Front pilot for initial locating the broach in the hole
Roughing and finishing teeth for metal removal
Finishing and burnishing teeth for fine finishing
Rear pilot and follower rest or retriever
Manufacturing Technology
There are different types of broaching machines which are broadly classified
According to purpose of use
general purpose
single purpose
special purpose
According to nature of work
internal broaching
external (surface) broaching
According to configuration
horizontal
vertical
According to number of slides or stations
single station type
multiple station type
indexing type
According to tool / work motion
intermittent (one job at a time) type
continuous type
Manufacturing Technology
Horizontal broaching machine
Horizontal broaching machines, typically shown in Fig. are the most
versatile in application and performance and hence are most widely
employed for various types of production. These are used for internal
broaching but external broaching work are also possible. The horizontal
broaching machines are usually hydraulically driven and occupies large
floor space.
Manufacturing Technology
Vertical broaching machine
Vertical broaching machines, typically shown in Fig.
occupies less floor space
are more rigid as the ram is supported by base
mostly used for external or surface broaching though internal broaching is also
possible and occasionally done.
Manufacturing Technology
Major advantages
Very high production rate (much higher than milling, planing, boring etc.)
High dimensional and form accuracy and surface finish of the product
Roughing and finishing in single stroke of the same cutter
Needs only one motion (cutting), so design, construction, operation and
control are simpler
Extremely suitable and economic for mass production
Manufacturing Technology
Limitations
Only through holes and surfaces can be machined
Usable only for light cuts, i.e. low chip load and unhard materials
Cutting speed cannot be high
Defects or damages in the broach (cutting edges) severely affect product
quality
Design, manufacture and restoration of the broaches are difficult and
expensive
Separate broach has to be procured and used whenever size, shape and
geometry of the job changes
Economic only when the production volume is large.
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