Broaching
1. Basic principle of broaching
Broaching is a machining process for removal of a layer of material of desired width and depth usually in
one stroke by a slender rod or bar type cutter having a series of cutting edges with gradually increased
protrusion as shown in fig 1. In shaping, attaining full depth requires a number of strokes to remove the
material in thin layers step-by-step by gradually in feeding the single point tool. Whereas, broaching
enables remove the whole material in one stroke only by the gradually rising teeth of the cutter called
broach. The amount of tooth rise between the successive teeth of the broach is equivalent to the in feed
given in shaping.
Fig. 1 Basic principle of broaching
Machining by broaching is preferably used for making straight through holes of various forms and sizes
of section, internal and external through straight or helical slots or grooves, external surfaces of
different shapes, teeth of external and internal splines and small spur gear etc. Fig 2 schematically
shows how a through hole is enlarged and finished by broaching.
Fig. 2 Schematic views of finishing hole by broaching
2. Construction and operation of broaching tool
Construction of broaching tool
Construction of any cutting tool is characterized mainly by
- Configuration
- Material and
- Cutting edge geometry
Configuration of broaching tool
Both pull and push type broaches are made in the form of slender rods or bars of varying section having
along its length one or more rows of cutting teeth with increasing height (and width occasionally). Push
type broaches are subjected to compressive load and hence are made shorter in length to avoid
buckling.
The general configuration of pull type broaches, which are widely used for enlarging and finishing
performed holes, is schematically shown in fig. 3.
Fig. 3 Configuration of a pull type of broach used for finishing holes
The essential elements of broach are:
- Pull end for engaging the broach in the machine
- Neck of shorter diameter and length, where the broach is allowed to fail, if at all, under
overloading
- Front pilot for initial locating the broach in the hole
- Roughing and finishing teeth for metal removal
- Finishing and burnishing teeth
- Rear pilot and follower rest or retriever
Broaches are designed mostly pull type to facilitate alignment and avoid buckling. The length of the
broach is governed by
- Type of broach: Pull or push type
- Number of cutting edges and their pitch depending upon the work material and maximum
thickness of the material layer to be removed
- Nature and extent of finish required
Keeping in view that around 4 to 8 teeth remain engaged in machining at any instant, the pitch or gap. p
of teeth is simply decided from
where, L- length of the hole or job.
The total number of cutting teeth for a broach is estimated from,
Tn ≥ (total depth of material)/ tooth rise, a1 (which is decided based on the tool-work materials and
geometry).
Broaches are generally made from solid rod or bar. Broaches of large section and complex shape are
often made by assembling replaceable separate sections or inserting separate teeth for ease of
manufacture and maintenance.
Material of broach
Being a cutting tool, broaches are also made of materials having the usual cutting tool material
properties, i.e. high strength, hardness, toughness and good heat and wear resistance.
For ease of manufacture and resharpening the complex shape and cutting edges, broaches are mostly
made of HSS (high speed steel). To enhance cutting speed, productivity and product quality, now-a-days
cemented carbide segments (assembled) or replaceable inserts are also used specially for stronger and
harder work materials like cast irons and steels. TiN coated carbides provide much longer tool life in
broaching. Since broaching speed (velocity) is usually quite low, ceramic tools are not used.
Geometry of broaching teeth and their cutting edges
Fig. 4 shows the general configuration of the broaching teeth and their geometry. The cutting teeth of
HSS broaches are provided with positive radial or orthogonal rake (5° to 15°) and sufficient primary and
secondary clearance angles (2° to 5°and 5° to 20°respectively) as indicated in fig. 4.
Fig.4 Geometry of teeth of broaching tools
Small in-built chip breakers are alternatively provided on the roughing teeth of the broach as can be
seen in fig. 2 to break up the cutting chips and thus preventing them from clogging the chip spaces and
increasing forces and tool wear. More ductile materials need wider and frequent chip breakers.
3. Broaching operation
Like any other machining, broaching is also accomplished through a series of following sequential steps:
- Selection of broach and broaching machine
- Mounting and clamping the broach in the broaching machine
- Fixing workpiece in the machine
- Planning tool-wok motions
- Selection of the levels of the process parameters and their setting
- Conducting machining by the broach
Selection of broach and broaching machine
There are various types of broaches available. The appropriate one has to be selected based on
- Type of job; size, shape and material
- Geometry and volume of work material to be removed from the job
- Desired length of stroke and the broach
- Type of the broaching machines available or to be used
Broaching machine has to be selected based on
- The type, size and method of clamping of the broach to be used
- Size, shape and material of the work piece
- Strength, power and rigidity required for the broaching machine to provide the desired
productivity and process capability.
Mounting and clamping broach in the machine
Fig. 5 Mounting and clamping pull type broach
The broach needs to be mounted, clamped and moved very carefully and perfectly in the tool holding
device of the broaching machines which are used for huge lot or mass production with high accuracy
and surface finish.
Pull type and push type broaches are mounted in different ways. Fig. 5 typically shows a broach pull
head commonly used for holding, clamping and pulling pull type broach. Just before fitting in or
removing the broach from the broach pull head (Fig. 5 (a)), the sliding outer socket is pushed back
against the compression spring. After full entry of the pull end of the broach in eh head the socket is
brought forward which causes locking of the broach by the radially moving strips as shown in fig 5 (b).
Pull type broaches are also often simply and slight flexibly fitted by a suitable adapter and pin as can be
seen in fig 6.
Fig 6 Fitting pull type broach by an adapter and a pin
Mounting of workpiece or blank in broaching machine
Broaching is used for mass production and at fast rate. The blanks are repeatedly mounted one after
another in an appropriate fixture where the blanks can be easily, quickly and accurately located,
supported and clamped.
In broaching, generally the job remains fixed and the broach travels providing cutting velocity. Fig. 7
schematically shows a typical method of mounting push or pull type of external broach for through
surfacing, slotting or countering.
Fig. 7 Mounting external broach for surfacing and slotting
Tool-work motions and process variables
Any machining is associated with 2 to 5 tool-work motions as well as cutting velocity, feed and depth of
cut as process variables. But broaching operation/machine needs only one motion which is cutting
motion and is mostly imparted to the tool. In broaching feed is provided as tooth rise. The magnitude of
cutting velocity, Vc is decided based on the tool-work materials and the capability of the broaching
machine. In broaching metals and alloys, HSS broaches are used at cutting velocity of 10 to 20 m/min
and carbide broaches at 20 to 40 m/min. The value of tooth rise varies within 0.05 mm to 0.2 mm for
roughing and 0.01 to 0.04 mm for finishing teeth. Some cutting fluids are preferably used mainly for
lubrication and cooling at the chip-tool interfaces.
Fig. 8 Mounting blank in broaching machine
Fig. 8 typically shows mounting of blank in fixture. But occasionally the job is travelled against the
stationary broach as in continuous working type broaching machine.
4. Different types of broaches and their applications
Broaching is getting more and more widely used, wherever feasible, for high productivity as well as
product quality. Various types of broaches have been developed and are used for wide range of
applications.
- Internal broaching or external broaching
- Pull type or push type
- Ordinary cut or progressive type
- Solid, sectional or modular type
- Profile sharpened or form relieved type
Internal and external broaching tool
Fig. 9 Internal broaching-tools and applications
Internal broaching tools are used to enlarge and finish various contours in through holes performed by
casting, forging, rolling, drilling, punching etc. Internal broaching tools are mostly pull type but may be
push type also for lighter work. Pull type internal broaching tools are generally provided with a set of
roughing teeth followed by few semi-finishing teeth and then some finishing teeth which may also
include a few burnishing teeth at the end. The wide range of internal broaching tools and their
applications include:
- Through holes of different form and dimensions as indicated in fig. 9
- Non-circular holes and internal slots (fig. 9)
- Internal keyway and splines
- Teeth of straight and helical fluted internal spur gears as indicated in fig. 9
External broaching
External surface broaching competes with milling, shaping and planing and wherever feasible,
outperforms those processes in respet of productivity and product quality. External broaching tools may
be both pull and push type.
Major applications of external broaching are:
- Un-obstructed outside surfacing, flat, peripheral and contour surfaces (fig. 11 (a))
- Grooves, slots, keyways etc on through outer surfaces of objects (fig. 8)
- External splines of different forms
- Teeth of external spur gears or gear sectors as shown in fig. 10 and 11 (b)
Fig. 10 Machining external gear teeth by broaching
Fig. 11 Typical external broaching (a) making slot (b) teeth of gear sector
External broaching tools are often made in segments which are clamped in fixture for operation.
Pull type and push type broaches
During operation a pull type broach is subjected to tensile force which helps in maintaining alignment
and prevents buckling. Pull type broaches are generally made as a lone single piece and are more widely
used, for internal broaching in particular. Push type broaches are essentially shorter in length (to avoid
buckling) and may be made in segments. Push type broaches are generally used for external broaching,
preferably, requiring light cuts and small depth of material removal.
Ordinary-cut and progressive type broach
Fig. 12 Progressive-cut type broaches: (a) single bar and (b) double bar type
Most of the broaches fall under the category of ordinary-cut type where the teeth increase in height or
protrusion gradually from tooth to tooth along the length of the broach. By such broaches, work
material is removed in thin layers over the complete form. Whereas, progressive-cut type broaches have
their teeth increasing in width instead of height. Fig. 12 shows the working principle and configuration
of such broach.
Solid, sectional and module type broaches
Fig. 13 (a) Solid, (b) Sectional and (c) Segmental broaches
Broaches are mostly made in single pieces especially those used for pull type internal broaching. But
some broaches called sectional broaches, are made by assembling several sections or cutter-pieces in
series for convenience in manufacturing and resharpening and also for having little flexibility required by
production in batches having inter batch slight job variation. External broaches are often made by
combining a number of modules or segments for ease of manufacturing and handling. Fig. 13 typically
shows solid, sectional and segmental (module) type broaches.
Profile sharpened and form relieved type broaches
Like milling cutters, broaches can also classified as
Profile sharpened type broaches
Such cutters have teeth of simple geometry with same rake and clearance angles all over the cutting
edge. These broaches are generally designed and used for machining flat surface(s) or circular holes.
Form relieved type broaches
These broaches, being used for non-uniform profiles like gear teeth etc. have teeth where the cutting
edge geometry is more complex and varies point-to-point along the cutting edges. Here the job profile
becomes the replica of the tool form. Such broaches are sharpened and resharpened by grinding at their
rake faces unlike the profile sharpened broaches which are ground at the flank surfaces.
Broaching machines
The unique characteristics of broaching operation are
- For producing any surface, the form of the tool (broach) always provides the generatrix and
cutting motion (of the broach relative to the job surface) provides Directrix.
- So far as tool-work motions, broaching needs only one motion and that is the cutting motion
(velocity) preferably being imparted to the broach.
Hence design, construction and operation of broaching machines, requiring only one such linear motion,
are very simple. Only alignments, rigidity and reduction of friction and wear of slides and guides are to
be additionally considered for higher productivity, accuracy and surface finish.
Broaching machines are generally specified by
- Type; horizontal, vertical
- Maximum stroke length
- Maximum working force (Pull or push)
- Maximum cutting velocity possible
- Power
- Foot print
Most of the broaching machines have hydraulic drive for the cutting motion. Electro-mechanical drives
are also used preferably for high speed of work but light cuts.
There are different types of broaching machines which are broadly classified as
According to purpose of use
- General purpose
- Single purpose
- Special purpose
According to nature of work
- Internal broaching
- External (surface) broaching
According to configuration
- Horizontal
- Vertical
According to number of slides or stations
- Single station type
- Multiple station type
- Indexing type
According to tool/work motion
- Intermittent (one job at a time) type
- Continuous type
Some of the broaching machines are discussed here.
Horizontal broaching machine
Fig. 14 Horizontal broaching machine
Horizontal broaching machines, typically shown in fig. 14 are the most versatile in application and
performance and hence are most widely employed for various types of production. These are used for
internal broaching but external broaching work is also possible. The horizontal broaching machines are
usually hydraulically driven and occupies large floor space.
Vertical broaching machines, typically shown in fig. 15
Fig. 15 Vertical broaching machine
The vertical broaching machines:
- Occupies less floor space
- Are more rigid as the ram is supported by base
- Mostly used for external or surface broaching though internal broaching is also possible and
occasionally done.
High production broaching machine
Fig 16 Continuous broaching
Broaching operation and broaching machines are as such high productive but its speed of production is
further enhanced by:
- Incorporating automation in tool-job mounting and releasing
- Increasing number of workstations or slides for simultaneous multiple production
- Quick changing the broach by turret indexing
- Continuity of working
Fig 16 schematically shows the principle and methods of continuous broaching, which is used for fast
production of large number of pieces by surface broaching.
6. Advantages and limitations of broaching
Advantages
- Very high production rate (much higher than milling, planing, boring etc)
- High dimensional and form accuracy and surface finish of the product
- Roughing and finishing in single stroke of the same cutter
- Needs only one motion (cutting), so design, construction, operation and control is simpler
- Extremely suitable and economic for mass production.
Limitations
- Only through holes and surfaces can be machined
- Usable only for light cuts i.e. low chip load and soft materials
- Cutting speed cannot be high
- Defects or damages in the broach (cutting edges) severely affect product quality
- Design, manufacture and restoration of the broaches are difficult and expensive
- Separate broach has to be procured and used whenever size, shape and geometry of the job
changes
- Economic only when volume of production is high
Questions
1. Explain the basic principle of broaching with the help of neat diagram.
2. Explain the construction of broaching tool with respect to configuration, material and cutting
tool geometry.
3. Explain the broaching operation with respect to selection of broach and broaching machine,
mounting and clamping broach in the machine, mounting of workpiece or blank in broaching
machine and tool-work motions and process variables.
4. Explain the following type of broaching tools along with their applications
a. Internal broaching tool
b. External broaching tool
c. Pull and push type broaching tool
d. Ordinary cut and progressive type broaching tool
e. Solid, sectional and module type broaching tool
f. Profile sharpened type broaching tool
g. Form relieved type broaching tool
5. State how the broaching machines are specified.
6. State various advantages and limitations of broaching process.
