Broaching & Sawing Processes: General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

Broaching & Sawing Processes
General Manufacturing Processes Engr.-20.2710

Instructor - Sam Chiappone
Broaching
 Broaching is the process of removing metal with a
tool which has “teeth” arranged in a row. Each
tooth is successively higher than the previous
tooth and removes more material. In broaching,
one stroke or cycle of the machine produces a
finished part.
 Broaching is used to produce both internal and
external features. Production rates are high and
tolerances of +/- .0005” are possible.
GMP-20.271
Rensselaer Polytechnic Institute Chiappone
Broaching
GMP-20.271
Broaching
GMP-20.271
Broaching
GMP-20.271
Broaching
 Chip Formation
– Chip formation involves three basic requirements:
» The cutting tool must be harder than the part
material
» There must be interference between the tool and the
part as designated by the feed rate and cut per tooth
» There must be a relative motion or cutting velocity
between the tool and workpiece with sufficient force
to overcome the resistance of the part material.
http://www.generalbroach.com
GMP-20.271
Broaching
Tool Feed Direction
Gullet Tool
Depth of
cut per tooth
Workpiece
GMP-20.271
Broaching
 Chip Formation
– As long as these three conditions exist, the portion of
the material being machined that interferes with the free
passage of the tool will be displaced to create a chip.
– Many combinations exist that may fulfill such
requirements.
– Variations in tool material and tool geometry, feed and
depth of cut, cutting velocity, and part material have an
effect not only upon the formation of the chip, but also
upon cutting force, cutting horsepower, cutting
temperatures, tool wear and tool life, dimensional
stability, and the quality of the newly created surface.
GMP-20.271
Broaching
 The Mechanics of Chip Formation
– Empirical metal-cutting studies reveal several important
characteristics of the chips formed during the broaching process:
» The cutting process generates heat
» The thickness of the chip is usually greater than the thickness of the
layer from which it came
» The hardness of the chip is usually much greater than the hardness of
the parent material, and
» The other three relative values are all affected by changes in cutting
conditions and in properties of the material to be machined
GMP-20.271
Broaching
 The Mechanics of Chip Formation
» These observations also indicate that the process of
chip formation is one of deformation or plastic flow
of the material, with the degree of deformation
dictating the type of chip that will be produced.
GMP-20.271
Broaching
 Plastic Deformation
– Originally, it was thought that chips formed in metal
cutting were created in much the same way that wood
chips are formed when split by an axe. This may be
partially true for brittle materials such as cast iron, but
it does not hold true for the majority of metals. The
process by which chips are formed with metal-cutting
tools is called plastic deformation, and was first
described by Rosenhain at the Stratsfordshire Iron and
Steel Institute in 1906.
GMP-20.271
Broaching
 Plastic Deformation
– What actually happens in this shearing process is that the metal
immediately ahead of the cutting edge of the tool is severely
compressed resulting in temperatures high enough to allow plastic
flow.
– When the resisting stresses in a material exceed their elastic limit,
a permanent relative motion occurs and further deformation is
withstood.
– This strengthening is called work or strain hardening, and is
characteristic of all steels, but demonstrated most dramatically in
stainless steels.
GMP-20.271
Broaching
 How and Where Heat is Generated
– The force or energy that is put into the tool creates movement in a
group of metal atoms in the workpiece. This group is a finite
number of atoms which are forced to change their positions in
relationship to each other.
– As the atoms in the metal ahead of the tool are disturbed, the
friction involved in their sliding over one another is thought to be
responsible for 60% or more of the total heat generated.
– This internal friction, and the heat it generates, can be compared to
the friction and heat caused by bending a paper clip back and forth
until it breaks.
GMP-20.271
Broaching
 How and Where Heat is Generated
– As the tool continues to push through the work piece, a chip
eventually slides up the cutting face of the tool. This sliding creates
an external friction which again releases heat. This external friction
accounts for about 30% of the total heat generated.
– The third area of heat generation is on the land or flank of the tool.
This area accounts for about 10% of the heat generated. This is
assuming that the tools are sharp and made correctly as far as
clearance angles and face angles are concerned. As the tool wears,
the above percentages will vary, especially when there is excess
wear on the land, or if the clearance angle is insufficient for the
material or the part configuration. This contact zone will actually
increase as the part continues to close in after the cut resulting in
extremely high pressures on the land area of the tool.
GMP-20.271
Advantages & Disadvantages
– Advantages
» Rough to finish in one pass
» Production rates are high
» Cutting time is quick
» Rapid load and unload of parts
» External and internal features
» Any form that can be produced on a broaching tool can be
produced
» Production tolerances are excellent
» Surface finishes are equal to milling
» Operator skill is low
GMP-20.271
Advantages & Disadvantages
– Disadvantages
» Tooling cost can be high
» In some cases--not suited for low production rates
» Parts to be broached must be strong enough to withstand the
forces of the process
» Surface to be broached must be accessible
GMP-20.271
Methods of Operation
– Pull broaching - broach is pulled through or across
stationary work
– Push broaching - broach is pushed through or across
work
– Surface broaching - either the work or the broach
moves across the other
– Continuous broaching - the work is moved
continuously against stationary broaches. The path of
the movement may be straight or circular.
GMP-20.271
Machines
– Vertical single and double slide - Table moves part into
position for broaching, part is broached and the table
retracts for unloading.
» Vertical push broaching - Used for internal features such as
holes, rounds, or slots.
» Vertical pull down
 Tool is suspended above work
 Lowered into pull mechanism in the base of the machine
 Advantages
– Part positioning is easy

– Large parts are handled efficiently
GMP-20.271
Machines
– Vertical single and double slide
GMP-20.271
Machines
– Horizontal
» Versatile machine capable of producing internal and external
features
 key-ways
 gear teeth
 riffling
– High cutting speeds in the range of 10-40ft/min with

return speeds of 110 ft/min
– MRR of ¼ in per stroke is possible
GMP-20.271
Methods of Operation
GMP-20.271
Machines
– Horizontal
GMP-20.271
Machines
– Rotary
» Parts are mounted to a rotating table and are moved to different
stations for different operations
» Primarily used on small parts
» Typical operations include:
 Slotting
 Holes
 Key-ways
GMP-20.271
Broaching Tools Design &
Construction
 Considerations
– Material to be broached
– Size and shape of cut
– Quality of surface finish
– Part tolerance
– Productions rates
– Type of machine
– Workholding method
– Strength of the workpiece
GMP-20.271
Sawing
 Depending on part tolerance, sawing can be a vital
first operation or the total process.
GMP-20.271
Machines Classifications
 Reciprocating saws
– Horizontal hacksaw and
vertical sawing machines
– Light to heavy duty
– Simple and most
economical to operate
– Manual to fully automatic
feed mechanisms
– Uses blades similar to
hacksaw blades
GMP-20.271
 Circular saws
– Sometimes called cold
sawing machines
– Saw blades are large and
rotate at low Rpms
– Cutting is similar to a
milling operation due to
geometry of saw blade
GMP-20.271
 Band saws
– Irregular shapes
– Very versatile
– Profile cuts
– Internal cuts
– external configurations
– Blades are continuous
» HSS - Carbide tipped
» Diamond impregnated
» Filing
GMP-20.271
 Band saws
1 3
GMP-20.271
Saw Blades
 Circular
 Straight
 Band
GMP-20.271
Saw Blades
 Terminology
– Set of the blade - Directional offset, left-right, from the
blades centerline. Sometimes referred to as the “kref.”
The kref provides clearance for the blade as it cuts
through the work.
– Straight - one tooth left one tooth right. Typically used
for brass, copper, and plastic.
– Raker - Three tooth sequence, left, right, straight.
Typically used for steel and cast iron.
– Wavy - Alternate arrangement of several teeth to the
right and left. Used to cut tubes and light sheet metal.
GMP-20.271
Saw Blades
GMP-20.271
Saw Blades
 Tooth forms
– Variable positive
– Variable
– Standard
– Skip
– Hook
GMP-20.271

Broaching & Sawing Processes: General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

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Broaching & Sawing Processes: General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

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Available Formats

Broaching & Sawing Processes

General Manufacturing Processes Engr.-20.2710

 Lowered into pull mechanism in the base of the machine

– Part positioning is easy

– High cutting speeds in the range of 10-40ft/min with

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