Broaching

Broaching is one of the metal machining operations done by a multipoint cutting tool called broaching tool or broach
There are two main types of broaching: linear and rotary Commonly machined surfaces include circular and non-circular holes, splines, keyways, and flat surfaces.

The broaching is a high productivity method as so many cutting edges work to machine the workpiece at a time
Broaching works best on softer materials, such as brass, bronze, copper alloys, aluminium, graphite, hard rubbers, wood, composites, and plastic.

The final shape may be a smoother, flatter surface, larger hole, complex splined, toothed notched curved, helical, or some other irregularly shaped section. Almost any irregular cross-section can be broached as long as all surfaces of the section remain parellel to the direction of broach travel.
Function: roughing, sizing, or burnishing he only limitations on broaching are that there are no obstructions over the length of the surface to be machined, the geometry to be cut does not have curves in multiple [8] planes, and that the workpiece is strong enough to withstand the forces involved.

Tooling is the heart of any broaching process. The broaching tool is based on a concept unique to the process - rough, semi-finish, and finish cutting teeth combined in one tool or string of tools.

The slab broach is the simplest surface broach. It is a general purpose tool for cutting flat surfaces Slot broaches (G & H) are for cutting slots of various dimensions at high production rates. Slot broaching is much quicker than milling when more than one slot needs to be machined, because multiple broaches can be run through the part at the same time on the same broaching machine. Contour broaches are designed to cut concave, convex, cam-, contoured, and irregular shaped surfaces Pot broaches are cut the inverse of an internal broach; they cut the outside diameter of a cylindrical workpiece. They are named after the pot looking fixture in which the broaches are mounted; the fixture is often referred to as a "pot". The pot is designed to hold multiple broaching tools concentrically over its entire length. Straddle broaches use two slab broaches to cut parallel surfaces on opposite sides of a workpiece in one pass. This type of broaching holds closer tolerances than if the two cuts were done independently

Examples of the different shapes produced by internal and external broaching are shown in Figure 2.2.

Machine tool grinding machine

Description Improve surface finish, abrade hard material, and tighten the tolerance on flat and cylindrical surfaces by removing small amount of material.

Process used to finish workpieces that must show high surface quality (e.g., low surface roughness) and highaccuracy of shape and dimension. Applied if: Material too hard to be machined Close tolerances required perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with different tools

Lathe machine

Planner Drilling machine Honing Milling machine

Produces surfaces.

The tool is called a milling cutter

o making flat surfaces o grooving, slitting and parting o helical grooving

Boring machine shaper

Turning Milling Drilling Planing Shaping Broaching Gear cutting Boring

Polishing Buffing Lapping Grinding Honing Superfinishing

Abrasive jet machining Ultrasonic machining Water jet machining Magnetic abrasive finishing

Electro chemical machining Electro Discharge machining Laser beam machining Plasma beam machining

Figure 2: Classification of Machining Processes [2]