MACHINE TOOL AND

MACHINING
Submitted By: Faisal Maqsood
Registration No: 2017-ME-527
Submitted to: Engr. Shahid Farooq
BROACHING MACHINES
Broaching

Definition:
■ Broaching is a method of removing metal by pushing or pulling a cutting tool called
a broach which cuts in a fixed path.
WORKING PRINCIPLE OF BROACHING
MACHINE:

• Work piece is fixed on fixture and broach is pulled or pushed. Sharp edges of broach
penetrate into work piece and due to shearing action plastic deformation of workpiece
takes place and metal removes in form of chips.
• Thickness of chip is approximately half the pitch. Chips are collected in to chip space
and it is removed when broach comes out from workpiece.
BROACHING MACHINES
BROACHING MACHINES

• Constructional Features:
1) Work holding fixture
2) Broaching tool
3) Drive Mechanism
4) Supporting frame.
BROACHING MACHINES
1)Work holding fixture
• Used to hold work piece in proper
position
• Some times it guides tools
• It is also used to rotate work piece in
cutting of helical gear.
• Three types of fixtures-Manual, semi
automatic, automatic.
• Manual fixtures are used for small
batches,
• Hydraulic and Pneumatic type semi
automatic or automatic fixtures are
used in mass production
BROACHING MACHINES
2) Broach Tool
■ Classification:
1) According to type of cut: -External broach
-Internal broach
2) According to method of cutting: -Push broach
-Pull broach
3) According to shape: -Solid broach
-Inserted broach
-Progressive broach
4) According to application: -Keyway broach
-Spline broach
-Helical cut broach
BROACHING MACHINES
2) Broach Tool
Classification:
■ Internal broach: Used to increase hole size and finishing
■ External broach: Used to make external shapes. Small segments are arranged in row in one
piece.
■ Push broach: It is pushed in work piece to remove material. It is having small length to reduce
possibility of bending of tool
■ Pull broach: Material is removed by pulling action of broach from work piece.
■ Solid broach: It is made from single bar stock. It has high dimensional accuracy. Entire broach
is replaced in case of wear of teeth.
■ Inserted broach: It is made of tool holder and inserts of HSS, carbides etc. Inserts are brazed
on tool holder.
■ Progressive broach: It is used for wide surfaces. Two pairs of rough teeth and finish teeth are
used. Surface is machined in one pass.
Types of Broaching Machines
■ Types of broaching machines
A) According to direction of broach travel.
1) Horizontal broaching machine
2) Vertical broaching machine
B) According to Method of operation.
1) Pull broaching machine
2) Push broaching machine
3) Surface broaching machine
4) Continuous broaching machine
C) According to Method of drive.
1) Mechanical Drive machine
2) Pneumatic drive machine
3) Hydraulic drive machine
D) According to type of operation.
1) External broaching machine
2) Internal broaching machine
Horizontal Broaching Machine.

• Usually pull type.

• Used for internal and external
broaching.
• Bed is approximately double size
than broach stroke
• Ram is hydraulically operated.
• Used to make keyways, splines,
slots etc.
Vertical Broaching Machine.

• It can be push type or pull type.

• Broach is held vertically.
• 2,4,6 broaches can be operated at
time.
• Stroke height is limited upto
1500mm.
• Less space is required compared to
horizontal machine.
• Hydraulic or electromechanical drives
can be used.
• Preferable for mass production.
Continuous Broaching Machine.

• Used for mass production of small

work pieces.
• Rotary or Horizontal type of
movement can be provided.
• In rotary machine, rotary table is
used. W/P is indexed and broaching
is done.
• In horizontal machine, conveyer
continuously moves and broach
remains steady.
Surface Broaching Machine.

■ Surface broaching machines have

their broaching tools attached to a
ram or rams forced in a straight
path along guide ways past the work
piece.
■ On some surface broaching
machines, the ram travels
horizontally, on others ram travels
vertically. When two rams are used,
the machines is called a duplex
broach.
Cutting tool for Broaching
The terminology of the broach is shown in the figure:
Broach tool nomenclature
Broach tool nomenclature
■ Pull end- connected to pulling head of broaching machine.
■ Front pilot- this locates the broach centrally with the hole to be broached.
■ Roughing teeth and semi finished teeth- used for removing most of metal in broaching.
■ Finishing teeth- meant for finishing the hole to the size and shape.
■ Rear pilot- meant for giving support to the broach after the last tooth leaving the work
piece.
■ Land- top portion of teeth.
■ Clearance or back off angle- back of the tooth sloped to give clearance angle.
■ Rake or face angle- angle made by sloping the front face of tooth. Depends upon work
piece material.
■ Pitch- linear distance between one tooth to the next tooth. It is more in roughing teeth
than finishing teeth.
Broaching tool
Broaching tool
Broaching tool
External broaching tool
Broaching process

■ on a press – the tool is pushed

■ on a broaching machine – the tool is pulled
■ Using special machine – stationary broach
Broached shapes

■ Internal – holes and other round shapes, keyways, profiles, gears.

-Need leading hole to place the pilot
■ External – faces, T-shape, co-planar surfaces, gears
■ Holes calibration – Broach diameter slightly bigger than the hole.
Keyway broaches
Limitations of Broaching

1) Costly tool
2) Not suitable for small batch.
3) Less amount of material is removed
4) Proper fixtures are required.
5) Strains are produced in w/p
6) Surfaces should be parallel to broach travel axis.
Advantages of Broaching

1) High production rate.

2) Job is prepared in one stroke
3) High tool life
4) Internal and external machining can be done
5) 0.8micron finishing can be obtained
6) Interchangeability of components can be done due to tolerances obtained in range.
7) Roughing and finishing can be done in single stroke
Specification of Broaching Machine

■ Power of the motor and its speed

■ Length of bed
■ Length of slide stroke
■ Rated pulling force
■ Cutting stroke speed
■ Number of speeds
■ Return stroke speed
■ Maximum size of cut
■ Weight of machine
■ Size and floor area
Thank You