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Broaching is a machining process used to cut internal and external surfaces. It involves pushing or pulling a broach tool through a workpiece to cut the desired shape. Round broaches cut cylindrical holes by gradually increasing the size of the hole with each successive tooth on the broach. Broaching produces a high output and is used for mass production, though broaches themselves are expensive tools. There are different types of broaches that can cut various internal and external shapes like holes, gears, and splines.
Broaching is a machining process used to cut internal and external surfaces. It involves pushing or pulling a broach tool through a workpiece to cut the desired shape. Round broaches cut cylindrical holes by gradually increasing the size of the hole with each successive tooth on the broach. Broaching produces a high output and is used for mass production, though broaches themselves are expensive tools. There are different types of broaches that can cut various internal and external shapes like holes, gears, and splines.
Broaching is a machining process used to cut internal and external surfaces. It involves pushing or pulling a broach tool through a workpiece to cut the desired shape. Round broaches cut cylindrical holes by gradually increasing the size of the hole with each successive tooth on the broach. Broaching produces a high output and is used for mass production, though broaches themselves are expensive tools. There are different types of broaches that can cut various internal and external shapes like holes, gears, and splines.
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, 6- finishing 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 = s z .b mm 2
for a key-way (single-spline) broach f = s z .b.n mm 2
for multi-spline broach f= s z . . D mm 2
for a round broach Where, s z 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 T m = ---------------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