Heaven’s Light is Our Guide

Rajshahi University of Engineering & Technology

Welcome to the Lecture

on
Surface Finishing Operations
(Broaching, Lapping, Honing)

Presented by-

Monjur Mourshed
Lecturer
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology
RUET, Bangladesh
 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

Broaching enables remove the whole material in one stroke only by the
gradually rising teeth of the cutter called broach.

A broach is effectively a collection of single point cutting tools arrayed in

sequence, cutting one after the other; its cut is analogous to multiple
passes of a shaper.

Broaches are shaped similar to a saw, except the teeth height increases
over the length of the tool.

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 Broaching
Broaching is a highly productive method of machining. Applications
include-

- making straight through holes of various forms and sizes of section

- internal and external surface smoothing through straight or helical
slots or grooves,
- to machine internal and external surfaces such as holes of circular,
square, or irregular shapes, teeth of external and internal splines,
profiles and small gears, keyways

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 Specifications of Broach and Broaching Machine
There are various types of broaches available. The appropriate one has to
be selected based on

ο type of the job; size, shape and material

ο geometry and volume of work material to be removed from the job
ο desired length of stroke and the broach
ο type of the broaching machines available or to be used

Broaching machine has to be selected based on

ο The type, size and method of clamping of the broach to be used
ο Size, shape and material of the work piece
ο Strength, power and rigidity required for the broaching machine to
provide the desired productivity and process capability.

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 Broaching Tool/ Broach
A broach is a long multi-tooth cutting tool with successively deeper cuts. Each tooth removes a
predetermined amount of material in a predetermined location. The total depth of material
removed in one path is the sum of the depth of cut of each tooth. Broaching can produce parts
with very good surface finish and dimensional accuracy

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 Broaching Machine Types
According to nature and direction of cutting
Horizontal Broaching Machine
Vertical Broaching Machine
Continuous Broaching Machine
According to the purpose
Internal Broaching Machine
External Broaching Machine
According to the construction of the broach
tool
Solid Broaching Machine
Inserted tooth Broaching Machine
Progressive Cut Broaching Machine
Built-up Broaching Machine
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According to the function
Keyway Broaching Machine
Burnishing Broaching Machine
Splining Broaching Machine
Round-Hole Broaching Machine
Surface Broaching Machine
According to the number of main slides
Single Broaching Machine
Double Broaching Machine
Multiple slides Broaching Machine
According to the motion of Broach tool
Straight-line Broaching Machine
Stationery Broach tool Broaching
Machine
Horizontal Broaching Machine

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 Horizontal Broaching Machine…
•Mostly all are pull type.

•Both internal and external broaching can be done.

•Consists of a box type bed having length is twice the length of stroke.

•All modern machines are provided with hydraulic drive housed in the bed.

•Job located in the adapter which is fitted on front vertical face.

•Small end is connected to hole of the job, then connected to pulling end
which is mounted on front end of ram.

•Ram is connected to hydraulic drive.

•Rear end is supported by guide.

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Vertical Broaching Machine

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 Vertical Broaching Machine…
• The working of vertical broaching machine is similar to that of horizontal
broaching machine
• Occupies less floor space
• 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.

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Continuous Surface Broaching Machine

• This type is used for mass production of smaller parts.

• The broaches are fitted into a belt driven by a set of pulleys, such that the
work piece is held normal to the broach.
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 Rotary Broaching Machine

• This machine has a rotary table and vertical column. The broach is fitted
horizontally above the table

• A series of fixtures are mounted on the rotary table for locating and
holding work pieces. They move past the stationary broaches

• Rotary broaching machines are limited to small parts. They are used for
squaring distributor shaft, slotting and the facing of smaller parts
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Broaching Tool/ Broach

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 Broaching Tool/ Broach…
Pull end- connected to pulling head of broaching machine for engaging the
broach
Neck- shorter diameter and length, where the broach is allowed to fail, if at all,
under overloading
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 fine 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. The pitch p, of teeth
is simply decided from 1.25pL= to 1.5L ; where, L = length of the hole or job.
It is more in roughing teeth than finishing teeth.
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Broaching Operations … Pull & Pull Type
On a press – the tool is pushed
On a broaching machine – the tool is pulled
Using special machine – stationary broach

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Broaching Operations

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Broaching Operations…

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 Broaching…Advantages
 Both roughing and finishing operations are completed in one pass of
the tool, giving high production rate
 Any form that can be reproduced on a broaching tool can be machined
by broaching process
 Actual cutting time is a matter of few seconds. Rapid loading and
unloading fixtures keep total production time to a minimum
 Internal or external surfaces can be machined within close tolerances.
The accuracy of surface finish is of the order of 0.1 micron
 Simple operation and a possibility of automation
 Broaches have a long life
 Broad range of materials can be successfully machined with proper
broach design and setup conditions

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 Broaching…Limitations
 Tooling cost is very high. So preferred for mass production only
 The broaching tool is made for a particular job only
 Surface to be broached should not have any obstruction
 Work-piece to be broached should be rigid and strong enough to
withstand the cutting forces
 Broaching is not recommended for the removal of large amount of
stock and short-run jobs
 All the elements of the broached surface must be parallel to the axis of
travel

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 Grinding
• Grinding is the most common form of abrasive machining. It is a
material cutting process which engages an abrasive tool whose cutting
elements are grains of abrasive material known as grit. These grits are
characterized by sharp cutting points, high hot hardness, chemical
stability and wear resistance
• The grits are held together by a suitable bonding material to give shape
of an abrasive tool

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Major advantages and applications of grinding
Advantages
• A grinding wheel requires two types of specification
– Dimensional accuracy
– Good surface finish
– Good form and locational accuracy applicable to both hardened and
unhardened material

Applications
• Surface finishing
• Slitting and parting
• De-scaling , De-burring
• Stock removal (abrasive milling) finishing of flat as well as cylindrical
surface
• Grinding of tools and cutters and re-sharpening of the same.

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 Classification of Grinding Processes
Grinding machine is employed to obtain high accuracy along with very high class of surface
finish on the work piece. However, advent of new generation of grinding wheels and grinding
machines, characterized by their rigidity, power and speed enables one to go for high efficiency
deep grinding (often called as abrasive milling) of not only hardened material but also ductile
materials

Conventional grinding machines can be broadly classified as:

 Surface grinding machine
 Cylindrical (center type) grinding machine
 Center less grinding

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 Grinding Processes…Surface Grinding
In surface grinding, the spindle position is either horizontal or vertical, and the
relative motion of the work piece is achieved either by reciprocating the work
piece past the wheel or by rotating it. The possible combinations of spindle
orientations and work piece motions yield four types of surface grinding
processes illustrated in the figure---

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 Grinding Processes…Surface Grinding
This machine may be similar to a milling machine used mainly to grind flat surface. However,
some types of surface grinders are also capable of producing contour surface with formed
grinding wheel

Horizontal Grinding Machine Vertical Grinding Machine

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Grinding Processes…Cylindrical (center type) Grinding
In external cylindrical grinding (also center-type grinding) the work piece rotates and
reciprocates along its axis, although for large and long work parts the grinding wheel
reciprocates.

In internal cylindrical grinding, a small wheel grinds the inside diameter of the part. The work
piece is held in a rotating chuck in the headstock and the wheel rotates at very high rotational
speed. In this operation, the work piece rotates and the grinding wheel reciprocates.

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 Grinding Processes…Centerless Grinding
Center less grinding is a process for continuously grinding cylindrical surfaces in which the work
piece is supported not by centers or chucks but by a rest blade. The work piece is ground between
two wheels. The larger grinding wheel does grinding, while the smaller regulating wheel, which
is tilted at an angle i, regulates the velocity Vf of the axial movement of the work piece.

Center less grinding can also be external or internal,

traverse feed or plunge grinding. The most common
type of center less grinding is the external traverse
feed grinding.

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 Dressing
Dressing is the conditioning of the wheel surface which ensures that grit cutting edges are
exposed from the bond and thus able to penetrate into the work piece material. Also, in dressing
attempts are made to splinter the abrasive grains to make them sharp and free cutting and also to
remove any residue left by material being ground.

Dressing therefore produces micro-geometry. The structure of micro-geometry of grinding wheel

determine its cutting ability with a wheel of given composition. Dressing can substantially
influence the condition of the grinding tool.

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 Truing
Truing is the act of regenerating the required geometry on the grinding wheel, whether the
geometry is a special form or flat profile. Therefore, truing produces the macro-geometry of the
grinding wheel.

Truing is also required on a new conventional wheel to ensure concentricity with specific
mounting system. In practice the effective macro-geometry of a grinding wheel is of vital
importance and accuracy of the finished work piece is directly related to effective wheel
geometry.

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 Lapping
Lapping is a machining operation, in which two surfaces are rubbed together
with an abrasive between them, by hand movement or by way of a machine.

In lapping, instead of a bonded abrasive tool, water or oil-based fluid

suspension of very small free abrasive grains (aluminum oxide and silicon
carbide, with typical grit sizes between 300 and 600) called a lapping
compound is applied between the work piece and the lapping tool.

More accuracy is obtained as heat & pressure are less in lapping. Material
removal in lapping usually ranges from .003 to .03 mm but many reach 0.08 to
0.1mm in certain cases.

Lapping is used to produce optical lenses, metallic bearing surfaces, gages, and
other parts requiring very good finishes and extreme accuracy

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 Lapping Process

The lapping tool is called a lap, which is made of soft materials like copper, lead or
wood. The lap has the reverse of the desired shape of the work part. To accomplish the
process, the lap is pressed against the work and moved back and forth over the surface.

The other form of lapping involves a softer material such as pitch or a ceramic for the
lap, which is "charged" with the abrasive. The lap is then used to cut a harder
material—the work piece. The abrasive embeds within the softer material which holds it
and permits it to score across and cut the harder material.
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 Lapping Process…
Abrasives of lapping
Al2O3 and SiC, grain size 5~100μm
Cr2O3, grain size 1~2 μm
B4C3, grain size 5-60 μm
Diamond, grain size 0.5~5 V
Lubricating materials of lapping
Machine oil
Rape oil
grease
Characteristics of lapping process:
 Use of loose abrasive between lap and the work piece
 Usually lap and work piece are not positively driven but are guided in contact with
each other
 Relative motion between the lap and the work should change continuously so that
path of the abrasive grains of the lap is not repeated on the work piece.

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 Honing
Honing is a low velocity abrading process in which stock is removed from
metallic or non metallic surfaces by bonded abrasive sticks.

In honing 6 to 8 honing sticks are held together and metal is removed by

rotating or reciprocating the holder.

Honing tool is rotated at a speed of 0.5 - 2.5 m/s and reciprocates at a speed of
0.2 – 0.5 m/s.

Most honing is done on internal cylindrical surface, such as automobile

cylindrical walls. Besides-
 Honing improves the accuracy and surface finish of automobile cylinder
bores, hydraulic cylinders, and similar parts
 Produce high degree of surface smoothness and dimensional accuracies for
taper shapes, gear teeth, roller bearings, bores
 It is effective on almost all ferrous or non ferrous material in a hardened or
soft condition
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 Honing Process
Honing is a finishing process performed by a honing tool, which contains a set of
bonded abrasive sticks
The sticks are equally spaced about the periphery of the honing tool. They are held
against the work surface with controlled light pressure, usually exercised by small
springs
The honing tool gives a complex rotational and oscillatory axial
motion, which combine to produce a crosshatched lay pattern of
very low surface roughness but the work piece is stationary

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 Honing Conditions
 It is desired that
- honing stones should not leave the work surface
- stroke length must cover the entire work length

 spindle speed is influenced by

- Material being honed- higher speeds used for materials that shear easily
- Hardness- harder the work piece, lower is the honing speed
- Surface finish- rough surfaces allow higher speeds

 Change of stroke length for required accuracy.

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 Super Finishing
Super finishing is a micro finishing process that produces a controlled surface
condition on parts which is not obtainable by any other method. The operation
which is also called ‘micro stoning’ consist of scrubbing a stone against a
surface to produce a fine quality metal finish.

This process is one type of honing , in which as compared to the honing less
pressure, high speed, huge amount of lubricant – coolant of low viscosity and
more contact area between work and abrasive face is kept.

Less heat is produced during super finishing and it is generally done on

external surfaces.

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 Super Finishing…Process
The process consists of removing chatter marks and fragmented or smear metal from the surface
of dimensionally finished parts. As much as 0.03 to 0.05 mm of stock can be efficiently removed
with some production applications, the process becomes most economical if the metal removal is
limited to 0.005 mm

Figure Schematic illustrations of the super finishing process for a cylindrical part. (a) Cylindrical
mircohoning, (b) Centerless microhoning.
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