Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

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BROACHING AND BROACHING MACHINES:

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 section, keyways, the teeth of internal gears, multiple spline holes, and flat surfaces (Fig. 23.21). A broach is a long multitooth cutting tool (Fig. 23.22a); the total depth of material removed in one stroke is the sum of the depths of cut of each tooth of the broach. A large broach can remove material as deep as 38 mm in one stroke. Broaching is an important production process and can produce parts with very good surface finish and dimensional accuracy. Although broaches can be expensive, the cost is justified with highquantity production runs. Broaches are available with various tooth profiles, including some with chip breakers. Broaches are made for the production of various external and internal shapes. The variety of surface broaches include slab (for cutting flat surfaces), slot, contour, dovetail, pot (for precision external shapes), and straddle.

Internal broach types include hole (for close tolerance holes, round shapes, and other shapes), keyway, internal gear, and rifling (for gun barrels). Irregular internal shapes are usually broached by starting with a round hole drilled or bored in the workpiece.

Broaching Machines:
Broaching machines either pull or push broaches are made either horizontal or vertical. Push broaches are usually shorter, generally in the range of 150-350mm.

___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

The difference between the pull and push broach is that Push broaches tend to straighten the hole, whereas pushing permits the broach to follow any irregularity of the leader home. Horizontal machines are capable of longer strokes. The force required to pull or push the broach depends on the strength of the workpiece material. The total depth and width of cut, and the cutting speed. Tooth profile and cutting fluids also affect this force. Broaching machines are relatively simple in construction, have only linear motions, and are usually attached hydraulically. Many styles of broaching machines are available, some with multiple heads, allowing a variety of shapes and parts to be produced, including helical spliners and rifles gun barrels. Sizes ranges form machines for making needlelike parts to those used for broaching gun barrels.

GEAR MANUFACTURING BY MACHINING:

Gears can be manufactured by casting, forging, extrusion, drawing, thread rolling, powder metallurgy, and blanking sheet metal (for making thin gears, such as those used in watches and small clocks). Nonmetallic gears can be made by injection molding and casting. The standard nomenclature for an involute spur gear is shown in Fig.

Gears may be small as those used in watches or as large as 9 m in diameter. The dimensional accuracy and surface finish required for gear teeth depend on its intended use.
___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

Poor gear-tooth-quality contributes to inefficient energy transmission and noise and adversely affects the gears frictional and wear characteristics. Submarine gears. For example, have to be of extremely high quality so as to reduce noise levels, helping the submarine avoid detection. There are two basic gear manufacturing methods which involve the machining of a wrought or cast gear blank: form cutting and generating.

Form Cutting:
In form cutting, the cutting tool is similar to a form-milling cutter made in the shape of the space between the gear teeth (Fig. 23.32a). The gear-tooth shape is reproduced by cutting the gear blank around its periphery. The cutter travels axially along the length of the gear tooth at the approximate depth to produce the gear tooth profile. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated, and the cutter proceeds to cut another tooth. The process continues until all teeth are cut. Each cutter is designed to cut a range of number of teeth. The precision of the form cut tooth profile depends on the accuracy of the cutter and on the machine and its stiffness. Form cutting is relatively simple process and can be used for cutting gear teeth with various profiles; however, it is a slow operation, and some types of machine require skilled labor. Consequently, it is suitable only for low-quantity production.

Gear Generating:
The cutting tool used in gear generating may be one of the following: 9 A pinion-shaped cutter. 9 A rack-shaped straight cutter. 9 A hob.

___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

a) Pinion-Shaped Cutter:
The pinion-shaped cutter can be considered as one of the gears in a conjugate pair and the other as the gear blank (Fig. 23.32b); it is used on machines called gear shapers (Fig. 23.32c). The cutter has an axis parallel to that of the gear blank and rotates slowly with the blank at the same pitch-circle velocity in an axial reciprocating motion. The train of gears provides the required relative motion between the cutter shaft and the gear-blank shaft.

b) Rack-Shaped Straight Cutter:

On a rack shaper, the generating tool is a segment of rack (Fig.23.32d) which reciprocates parallel to the axis of the gear blank. Because it is not practical to have more than 6 to 12 teeth on a rack cutter, the cutter must be disengaged at suitable intervals and returned to the starting point; the gear blank remains fixed.

c) A Hob:
A gear-cutting hob (Fig. 23.33) is basically a worm, or screw, made into a gear-generating tool by machining a series of longitudinal slots or gashes into it to form the cutting teeth. All
___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

motions in hobbing are rotary, and the hob and gear blank rotates continuously, much as two gears meshing until all teeth are cut. Hobs are available with one, two, or three threads. If the hob has a single thread and the gear is to have 40 teeth. For example, the hob and gear spindle must be geared together so that the hob makes 40 revolutions while the gear blank makes one revolution. Similarly, if a double-threaded hob is used, the hob would make 20 revolutions to the gear blanks one revolution.

Gear-Finishing Processes:
Several finishing processes are available to improve the surface quality of gears. The choice of process is dictated by the method of gear manufacture and whether the gears have been hardened by heat treatment.

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

Shaving:
The gear shaving process involves a cutter, made in the exact shape of the finished tooth profile, which removes small amounts of metal from the gear teeth. The cutter teeth are slotted or gashed at several points along its width, making the process similar to fine broaching. The motion of the cutter is reciprocating. Shaving and brushing can only be performed on gears with a hardness of 40 HRC or lower. Although the tools are expensive and special machines are necessary. Shaving is rapid and is the most commonly used process for gear finishing.

Burnishing:
The surface finish of gear teeth can also be improved by burnishing. Introduced in the 1960s, burnishing is basically a surface plastic-deformation process using a special hardened gear-shaped burnishing die that subjects the tooth surfaces to a surface-rolling action (gear rolling). Cold working of tooth surfaces improves the surface finish. However, burnishing, does not significantly improve gear-tooth accuracy.

Grinding, Honing, and Lapping:

For the highest dimensional accuracy, tooth spacing and form, and surface finish, gear teeth may be subsequently be ground, honed, and lapped. Specially-dresses grinding wheels are used for either forming or generating gear tooth surfaces. In FORM GRINDING, the shape of the grinding wheel is identical to that of the tooth spacing (Fig. 23.35a). In GENERATING, the grinding wheel acts in a manner similar to the gear generating cutter. The HONING tool is a plastic gear impregnated with fine abrasive particles. The process is faster than grinding and is used to improve surface finish. To further improve the surface finish, ground gear teeth are LAPPED using abrasive compounds with either a gear-shaped lapping tool (made of cast iron or bronze) or a pair of mating gears that are run together. Although production rates are lower and costs are higher, these finishing operations are particularly suitable for producing hardened gears of very high quality, long life, and quiet operation.

___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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Hafr-Al-Batin Community College

King Fahd University of Petroleum a nd Minerals Hand out # 10

MET 276: MACHINING

Mechanical Engineering Technology

_________________________________________________________________________________________________________

___________________________________________________________________________________ _________________________ Prepared by: Abdul Baseer

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