Supervision: Prof. Dr.
Refat El-Shiekh El-Zahry
The Academic Year: 2021/2022
Contents:
Introduction
Materials of Broaching
Type of internal Broaches
Spline Broaching
Product of Spline Broaching
single Spline Broaching(keyway)
Design of Cutting Tool
modern broaching machine
Introduction:
Broaching is a machining process where a sharp, hardened, toothed tool
removes material from a workpiece in a consistent, continuous, and accurate
way.
The process of broaching uses a tool with raised teeth of differing sizes that
precisely cut away a specified amount of material with every pass over the
workpiece.
The broaching tool has a series of teeth so arranged that they cut metal when the
broach is given a linear movement . The broach cuts away the material since its teeth
are progressively increasing in height.
Properly used, broaching can greatly increase productivity, hold tight tolerance, and
produce precision finishes. Tooling is the heart of broaching. The broach tool's
construction is unique for it combines rough, semi-finish, and finish teeth in one tool.
Materials of Broaching:
Based on cutting tool material properties .
Mostly made up of HSS. Ceramic are not used as low speed .
Broaching tools can be engineered and designed to fit the needs of any type of material
required to meet the needs of an application:
Brass
Aluminum
Titanium
Stainless Steel
Alloy Steel
12L14 Cold Finish Carbon Steel
Plastic
Cast Iron
Type of internal Broaches:
According to work and cutting speed there are many types of broaches forms such as in
hexagon , round ,rectangular , star , octagon , spline etc.
Different forms of broaches are shown in figure.
Spline Broaching:
Spline broaching, also known as round broaching, creates round, plain, or irregular
splines and spiral tooth forms. It can be used to create shafts, gears, and meshing
mechanical components. Spline broaching is the most common form of broaching and
uses a broach to form a series of ridges or teeth around the circumference of a pre-cut
hole. The process of spline broaching is an efficient method for creating serrated,
straight, and involute splines.
In the automotive industry, spline broaching is used to produce transmission and drive
shaft parts. The grooves created on a spline allow the efficient transfer of torque by
locking together separate components.
Product of Spline Broaching :
single spline Broaching(keyway):
Design of Cutting Tool:
Design of workpiece: spline width= 1 cm, length= 20 cm, diameter 5 cm.
1) Nominal allowance:
EQ.1
D: diameter of workpiece
L: length of workpiece
Then from table :
We will make straight spline so the cut per tooth
2)Calculate longitudinal chip space Area:
EQ.2
So chip space area EQ.3
K is a constant= (3-6)
Then
From table : take the Area = 62.7
Now we can choose the suitable tooth parameter from table :
Broach pitch: t = 20 mm
Depth of chip space: h = 8.1 mm
Land width: f = 6.5 mm
Radius: r = 4.5 mm
3)Calculating number of teeth:
EQ.4
The number of teeth in contact with the workpiece at the same time
EQ.5
Then take the number of finishing teeth = (4-8)
The total number of teeth = 20 + 6 = 26 tooth
4)Calculate the cutting force:
EQ.6
B: the total length of the cutting edges
EQ.7
Take: F = 22 kg/mm
Then
5)Calculate required cutting power:
EQ.8
V: cutting speed = 12 m/min
Calculate Motor power:
EQ.9
: motor efficiency = (0.6 – 0.9)
Take the efficiency = 0.85
S0
From standard code of motor we will choose
modern broaching machine:
Modern broaching dates to the 19th century, and the technology remained pretty
straightforward for most of the ensuing years. But today, the more than 150-year-old
technology has entered a new millennium with tool systems that allow broaching to be
integrated into today’s CNC machining environment.
The benefits of broaching on a CNC machine include fast speeds to create final forms,
high accuracy, low heat, high repeatability and easy operation utilizing standard drilling
G code. Broaching on a CNC machine also eliminates the need for secondary
operations.
Team Member
• Ahmed Saad
• Mohamed Sayad …..As A Team leader
• Kareem Mahmoud
• Abdullh Mohamed
• Mariam Alkiss
• Huda Ali
Thank you
