Arab Academy for Science, Technology,

and Maritime Transport

Material Removal Processes (IM 213)

Department of Industrial & Management Engineering

College of Engineering and Technology

Lecture 6 : Shaping and Broaching Processes

Shaping and Planing

 Shaping and Planning are machining by cutting processes

that are used to produce flat and contoured surfaces.
 Shaping:
The tool performs the linear reciprocating motion while the
workpeice performs the feed motion.
 Planing
The tool performs the feed motion while the workpeice
performs the linear reciprocating motion.

2
Hossam
Shaping Motions
Planing Motions
Mechanical Rocker Arm QRM
Hydraulic QRM
Shaping Tools

Straight shaping tool Goose neck shaping tool

Planing and Slotting Tools

Planing tool Slotting tool

8
Elements of Chip Formation

A  S .t
c

A  h.b
c A  b.S .Sin
c
Shaping Forces
F  k .A
v s c
A  S .t A  h.b
c c
F  k .S.t  k .b.h
v s s

t
A  b.S. sin  b
c sin 
Cutting Power

F .V
N  v
Cutting Power c 3
kW
60x10

F V
N  v
Motor Power m 3
60x10 
kW
m

Removal Rate VRR  103 V.S.t mm3/min

Useful Relations

3
Maximum cutting force 60x10  N
Fvx  m m N

3
Max depth of cut 60x10  N
tx  m m mm

V.S.k
s
12
Shaping Tool Travel

H  l  2
s

Bb b b
w 1 2

B
t 
m S.N 13
Shaping time

V  10  3 1
NH (1  )
s r
m/min

s
3
10
V
N Stroke/min
1
H (1  )
s r
s

B
t  min
m S.N

Bb b b mm
w 1 2
Broaching: Definition

Workpiece

Broach

Machining using a multipoint broach tool having

successive cutting points that project a distance
further than the proceeding one in the direction
perpendicular to the broach length.
Broach Tool
Geometry of Broach Teeth

cutting teeth (1 and 2) and finishing teeth (3)

Chip Space

Sz

hb

A cs
  Chip space number X=3 to 10
A
c
Acs : the chip cross section area of space, mm2
Ac : the area of longitudinal chip removed per tooth
which equals Szl.
Shapes Made by Broaching

Round Key way Spline Square Hexagonal

Broaching Operations

Workpiece length

Workpiece
length

Push
Pull