Broaching is a machining procedure that involves the removal of material from the workpiece with a specialized cutting tool known as a broach. Although broaching is usually used with machines specifically designed for it, it can also be done on lathes and mills.
Broaching on lathes and mills offers many advantages over dedicated broaching equipment, including flexibility, efficiency and space-saving. In this article, we’ll look at the broaching process, the benefits of broaching mills and lathes, and the maintenance of broaching equipment.
Types of Broaching
There are various kinds of broaching, such as external, internal surface, continuous, and internal. Internal broaching can cut internal forms and shapes, like Keyways or splines. External broaching removes external forms and shapes, such as bearings and gears.
eeSurface broaching can be used to cut smooth or contoured surfaces, and continuous broaching is employed to cut continuous, long-lasting shapes like screw threads.
Advantages of Broaching
One of the main benefits of broaching is its fast production rate. Broaching allows for the production of parts rapidly and accurately, with no involvement from the operator. Broaching also produces precise results that have tight tolerances and exact surface finishes. This is especially important in fields such as medicine and aerospace, where precision and safety are essential.
Broaching is also efficient because many cuts can be made in one pass. Furthermore, broaching is economical since it makes parts rapidly and accurately, so there is less requirement for costly second processes.
Broaching is possible using various equipment, including vertical and horizontal broaching equipment, surface broaching machines, or continuous broaching devices. Horizontal and vertical broaching equipment are the most popular kinds of broaching equipment that are utilized for both external and internal broaching. Surface broaching machines are used to broach surfaces, while continuous broaching machines create long, continuous forms.
A keyway broaching machine is designed specifically for keyway broaches and small-size broaches. By using the broaching machine, you can cut keys and then seize them. In most broaching machines, there is a cutter with multiple teeth.
CNC-operated electromechanical machines known as keyway broaching machines feature long, skinny tools with sharp teeth that are used to cut through metal. While keyway broaching can be done on hard metals, it is more difficult when it comes to soft metals, such as brass, copper, or aluminum.
Broaching Vs Other Machining Processes
Broaching is frequently compared to other machining processes like turning, milling and drilling. Milling is cutting using an instrument that rotates, whereas turning involves rotating the piece against a stationary tool. Drilling is the process of cutting an opening in the workpiece. Compared to these methods, broaching can produce more precise and precise results, resulting in more precise tolerances and smoother surfaces.
The broaching process involves several steps, such as preparation of the workpiece before setting the broaching machine up, choosing the appropriate broach, conducting the broaching process and then finishing the piece. The workpiece must be cleaned to ensure proper alignment and avoid damage from the broach and machine. The broaching equipment must be correctly set up and calibrated for accurate results.
The right broach needs to be chosen based on the required shape, as well as the tolerances. The broaching process involves pushing the broach into the workpiece and cutting the wanted shape as it moves. Finalizing operations, such as polishing and deburring, are carried out to create the desired finish on the surface.