BROACHING

Broaching is used for machining

through holes of any cross-sectional
shape, straight and helical slots,
external surfaces of various shape and
external and internal toothed gears.

Round Broach
1-pull end, 2-neck, 3-front taper,
4- front pilot, 5- cutting teeth, 6finishing teeth, 7-rear end

A round broach travels along the axis of

the hole being broached.
Since the teeth gradually increase in size
from the front to the rear end of the
broach, each successive tooth removes a
layer of material, thereby increasing the
size of the hole.

Round
Push
Broach

 If the force is
applied to the rear
end of the broach, it
is a push broach
and is in
compression.
To avoid buckling, a
push broach should
be shorter than a
pull broach and its
length usually does
not exceed 15
diameters.

 Although the cutting speeds used in

broaching are relatively low (2 to 15m
per min), the production capacity is
very high since the total length of the
cutting edges that are simultaneously
in operation is very great.

 The output in broaching can be raised

still higher if broaching machines with
a continuous working motion are used,
in conjunction with automatic
workpiece loading and unloading.
Broaches are expensive tools,
however, and their use is justified in
large-lot and mass production.

Circular Broach

 One classification of broaches, based on

their purpose is into internal broaches (for
machining holes) and external surface
broaches (for machining ruled surfaces of
open contour)
Broaches may have cutting teeth and
burnishers. The latter are non-cutting teeth
that compress, cold work, or burnish a thin
layer of metal.

Types of Internal Broach

Solid Round Broach

Sectional Round Broach

Helical Cut Broach

Burnishing Broach

Straight Spline Broach

Helical Spline Broach

Involute Spline Broach

Serration Spline Broach

Combination Broach

Square Broach

Geometric Elements of Broach

Teeth

 Sizing or finishing teeth have a

narrow straight wear land of f =
0.05 to 0.2 mm.
The back-off angles are assigned
in accordance with the kind of
operation and type of broach.

Broach back-off (relief) angles

Broach face (rake) angles

Cross-sectional area of
undeformed chip
f = sz.b mm2
for a key-way (single-spline) broach

f = sz.b.n mm2
for multi-spline broach

f= sz. . D mm2
for a round broach
Where,
sz cut per tooth

b spline width
n = number of splined
D = diameter of a round broach

 Total cross-sectional area of the

undeformed chip is

F=f.Z
Where, z is the number of teeth
simultaneously in operation.

Machining Time
L
Tm = ---------------K
1000.v.q
Where,
L- length of the working stroke
K- coefficient taking into consideration the ratio of the
working and the return stroke speeds, usually K =
1.4 to 1.5
v- cutting speed, m/min
q- number of workpieces broached simultaneously

Modes of Cutting
Plain broach

 Each successive
tooth removes a
thin chip on the
full width of
machined
surface, for
example, along
the full width of
a spline or a
key-way, along
the hole length
of the
circumference,
etc.

 Such a broach
is frequently
called a plain
broach and is
subjected to
high specific
cutting
pressure and
consequently,
to a high pull.

Group-cut Broach

 In group-cut
broaching,
the mode of
cutting is
arranged to
divide the
total
allowance
into small
number of
thick layers.

 In a group-cutting
broach all the
cutting teeth are
divided into two,
three or more
groups of teeth
having the same
diameter, but
increasing in
width within each
group.

 Thick, comparatively
narrow chips are
cut.
A broach based on
this mode of cutting
has a life that is
twice as long, on the
average, than that of
full-form broaches.

 An essential
drawback of
progressive
broaching is
the greater
difficulty
encountered in
manufacturing
the broaches.

Broaching Allowance
Broaching allowance is defined as the
total thickness of the metal to be
removed by broaching.
The nominal allowance for round holes
is,

A = 0.005 D + (0.1 to 0.2).L

Where,
D- basic diameter of the hole
L- length of the hole to be broached