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    History: 1850s World War 1 1920s 30s Today

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    Atif Attique
    Broaching is a machining process that uses a toothed tool called a broach to remove material. It was first used in the 1850s to cut keyways and has since been used to rifle gun barrels. Advances in broaching machines and tool grinding in the 1900s improved tolerances and reduced costs. Today, broaching can precision machine almost any material and form, though it is still developing new applications. Proper alignment of the broach, workpiece, and machine is critical to ensure quality machined surfaces. Broaching provides high production rates, close tolerances, and repeatable finishes suitable for mass manufacturing.

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    History: 1850s World War 1 1920s 30s Today

    Uploaded by

    Atif Attique
    56 views7 pages
    Broaching is a machining process that uses a toothed tool called a broach to remove material. It was first used in the 1850s to cut keyways and has since been used to rifle gun barrels. Advances in broaching machines and tool grinding in the 1900s improved tolerances and reduced costs. Today, broaching can precision machine almost any material and form, though it is still developing new applications. Proper alignment of the broach, workpiece, and machine is critical to ensure quality machined surfaces. Broaching provides high production rates, close tolerances, and repeatable finishes suitable for mass manufacturing.

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    Broaching is a machining process that uses a toothed tool called a broach to remove material. It was first used in the 1850s to cut keyways and has since been used to rifle gun barrels. Advances in broaching machines and tool grinding in the 1900s improved tolerances and reduced costs. Today, broaching can precision machine almost any material and form, though it is still developing new applications. Proper alignment of the broach, workpiece, and machine is critical to ensure quality machined surfaces. Broaching provides high production rates, close tolerances, and repeatable finishes suitable for mass manufacturing.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    56 views7 pages

    History: 1850s World War 1 1920s 30s Today

    Uploaded by

    Atif Attique
    Broaching is a machining process that uses a toothed tool called a broach to remove material. It was first used in the 1850s to cut keyways and has since been used to rifle gun barrels. Advances in broaching machines and tool grinding in the 1900s improved tolerances and reduced costs. Today, broaching can precision machine almost any material and form, though it is still developing new applications. Proper alignment of the broach, workpiece, and machine is critical to ensure quality machined surfaces. Broaching provides high production rates, close tolerances, and repeatable finishes suitable for mass manufacturing.

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    history

    The concept of broaching as a legitimate machining process can be traced back to the early 1850s. Early broaching applications were cutting keyways in pulleys and gears. After World War 1 broaching contributed to the rifling of gun barrels. Ad!ances in broaching machines and form grinding during the 1"#0s and $0s enabled tolerances to be tightened and broaching costs to become competiti!e with other machining processes. Today almost e!ery concei!able type of form and material can be broached. %t represents a machining operation that while known for many years is still in its infancy. &ew uses for broaching are being e!ised e!ery day.

    Introduction:
    Broaching is a machining operation which uses a toothed tool called a broach to remo!e material. The broach is used in a broaching machine which is also sometimes shortened to broach. %t is used when precision machining is re'uired especially for odd shapes. (roaching finishes a surface in a single pass which makes it !ery efficient. )ommonly machined surfaces include circular and non*circular holes splines and flat surfaces. Typical workpieces include small to medium si+ed castings forgings screw machine parts and stampings. E!en though broaches can be e,pensi!e broaching is usually fa!orable to other processes when used for high*'uantity production runs. (roaching is similar to planning competes with milling and boring and gi!es turning and grinding stiff competition. -roperly used broaching can greatly increase producti!ity hold tight tolerances produce precision finishes and minimi+e the need for highly skilled machine operators.

    Tooling:
    a Tooling is the heart of any broaching process. The broaching tool is based on a concept uni'ue to the process * rough semi*finish and finish cutting teeth combined in one tool or string of tools. A broach tool fre'uently can finish* machine rough surface in a single stroke. In its simplest form, a broach tool resembles a wood rasp. It is a slightly tapering round or flat bar with rows of cutting teeth located along the tool axis. In advanced forms, extremely complex cross-sections and tooth designs may be found, However, the basic axial, multi-toothed tool shape remains

    (roach -arts and -rocess.


    The process depends on the type of broaching being performed. /urface broaching is !ery simple as either the workpiece is mo!ed against a stationary surface broach or the workpiece is held stationary while the broach is mo!ed against it
    Internal broaching is more involved. The process begins by either clamping the workpiece into the workholder of the broaching machine or the workpiece is placed on a spherical work holder designed to automatically align the workpiece to the broach. The elevator of the broaching machine then lowers the pilot of the broach through the workpiece where the puller engages the broach pilot. The elevator then releases the top of the pilot and the puller pulls the broach through the workpiece completely. The workpiece is then removed from the machine and the broach is raised back up to

    reengage with the elevator.0 The broach usually only moves linearly, but sometimes it is also rotated to create a spiral spline or gun-barrel rifling.

    Alignment:
    -roper alignment of the broach workpiece and ram is the most important factor in all broaching operations. 1isalignment can cause drifting deflection and e!en breakage. Alignment Tips**%f a keyway broach drifts and cuts a taper try the following. 1. 2e!erse workpiece or turn broach so teeth face toward the back of the press. 2. 3et the bushing protrude abo!e the workpiece to gi!e more support to the back of the broach thereby helping to keep it aligned. %f a collared bushing is used place it upside down under the workpiece. 3. 1ake sure the broach is centered under the ram at the beginning of the cut. 4. %f the broach mo!es out of alignment after starting to cut back off the pressure on the ram and align the broach itself. 2epeat during successi!e cuts to ensure perfectly straight cuts.

    )utting fluids are used for three reasons


    . 4irst to cool the workpiece and broach /econd to lubricate cutting surfaces. Third to flush the chips from the teeth. 4ortified petroleum cutting fluids are the most common howe!er hea!y duty water soluble cutting fluids are becoming more popular

    1a5or types of broaching.


    -ull broaching * broach is pulled through or across stationary work -ush broaching * broach is pushed through or across work /urface broaching * either the work or the broach mo!es across the other

    )ontinuous broaching * the work is mo!ed continuously against stationary broaches. The path of the mo!ement may be straight or circular.

    Broaching machines:
    6arious kinds of (roaching machines are today used for manufacturing of gears some of those are described here.

    1*6ertical broaching machine.


    6ertical broaching is the type of machine which is used for broaching a piece part. The 6ertical (roaching 1achine comes in !arious types. All suited to different adaptations. To gi!e a more specific e,ample a machine where there is !ertical mounting of ram instead of the hori+ontal can be called as a !ertical broaching machine.

    #*7ori+ontal broaching machines.


    7ori+ontal (roaching 1achine refers to the machines that are applied for broaching a piece part. These were the first line of machines to be used for this process and still retain its popularity. 7ori+ontal broaching machines are a popular option to cut internal shapes of the gears.

    Ad!antages of broaching.

    ad!antages of broaching process are. 100 per cent uniform accuracy . 6arious contours and complicated irregular shapes can be easily broached . -roduction of broaching is e,ceptionally high hence most suitable for mass production . (roached surfaces are highly accurate in si+e and shape hence close tolerances can he maintained . /hort cycle time with high accuracy .

    2emarkably finished face . E,tremely economical. E,pertise not needed. The broaching process is not limited to only mass production8 some broaching machines are e!en suitable for small lots or e!en pieces production.

    9isad!antages :f broaching.
    %n some cases**not suited for low production rates /urface to be broached must be accessible -arts to be broached must be strong enough to withstand the forces of the process (roaching tool is too much costly.

    )onclusion.
    The broach tool and the broaching process are !ersatile and important and that anyone who works in the field of metals woods or plastics should be familiar with them.

    /ome prouducts of broaching .

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