WHAT IS BROACHING?

Broaching is a machining operation that involves

the use of a multiple-tooth cutting moved
linearly relative to the work piece in the
direction of the tool axis. The cutting tool is
called broach and the machine tool is called
broaching machine
TYPES OF BROACHING

1. Linear Broaching
2. Rotary Broaching
LINEAR BROACHING
. In linear broaching, which is the more common process,
the broach is run linearly against a surface of the
workpiece to effect the cut. Linear broaches are used
in a broaching machine
ROTARY BROACHING

A rotary broach is used in a lathe and screw machine .

both processes the cut is performed in one pass of
the broach, which makes it very efficient.
APPLICATIONS :
Broaching is used when precision machining is required,
especially for odd shapes. Commonly machined
surfaces include circular and non-circular holes
splines and keys and flat surfaces. Typical workpieces
include small to medium sized castings , forgings,
screw machine parts, and stampings.
 BASIC PRINCIPLE OF BROACHING
Broaching is a machining process for removal of a layer of
material of desired width & depth usually in one stroke by a
slender rod or bar type cutter having a series of cutting edges
with gradually increased protrusion. In shaping, attaining full
depth requires a number of strokes to remove the material in
thin layers step by step by gradually infeeding the single point
tool. Whereas broaching enables removing the whole material
in one stroke only by the gradually rising teeth of the cutter
called broach. The amount of tooth rise between the
successive teeth of the broach is equivalent to the infeed given
in shaping.
BROACHING OPERATION
MAJOR COMPONENTS BROACHING MACHINE
 BROACHING OPERATION

1.Like any other machining, broaching is also

accomplished through a series of following sequential
steps:
2. Selection of broach and broaching machine.
3.Mounting and clamping the broach in the broaching
machine.
4.Fixing workpiece in the machine.
5.Planning tool - work motions.
6.Selection of the levels of the process parameters and
their setting.
7.Conducting machining by the broach.
 SELECTION OF A BROACH & BROACHING
MACHINE
There are various types of broaches available. The appropriate one
has to be selected based on
1.Type of the job, size, shape and material.
2.Geometry and volume of work material to be removed from the
job.
3.Desired length of stroke and the broach.
4.Type of the broaching machines available or to be used.

Broaching machine has to be selected based on.

1.The type, size and method of clamping of broach to be used.
2.Size, shape and materials of the workpiece.
3.Strength, power and rigidity required for the broaching machine
to provide the desired productivity and process capability.
CHARACTESTICS OF A BROACHING OPERATION
The unique characteristics of broaching operation
are
For producing any surface, the form of the tool
(broach) always provides the Generatrix and the
cutting motion (of the broach relative to the job
surface) provides the Directrix.
So far as tool – work motions, broaching needs only
one motion and that is the cutting motion
(velocity) preferably being imparted to the broach.
SPECIFICATION

Broaching machines are generally specified by –

o Type : horizontal , vertical etc.
o Maximum stroke length
o Maximum working force (pull or push)
o Maximum cutting velocity possible
o Power
o Foot print
CLASSIFICATION OF BROACHING MACHINE

o According to the purpose of use

a. General purpose
b. Single purpose
c. Special purpose
o According to the nature of work
a. Internal broaching
b. External (surface) broaching
o According to the number of sides or station
a. Single station type
b. Multiple station type
c. Indexing type
CLASSIFICATION OF BROACHING MACHINE
(CONTINUE)

o According to the tool / work motion

a. Intermittent (one job at a time) type
b. Continuous type
ADVANTAGE OF BROACHING

o Very high production rate than milling , planning ,

boring etc.
o High dimensional and form accuracy and surface
finishing
o Roughing finishing in single stroke of same cutter
o Needs only one motion (cutting) , so design ,
construction , operation and control are simpler
o Extremely suitable and economic for mass
production
LIMITATIONS

o Only through holes and surface can be machined

o Usable only for light cuts . i.e. low chip load and
unhard materials
o Cutting speed can not be high
o Defects or damages in the broach severely affect
production quality
o Design , manufacture and restoration of the
broaches are difficult and expensive
o Separate broach has to be procured and used
whenever size , shape and geometry of the job
changes
o Economic only when the production volume is large