MANUFACTURING TECHNOLOGY

ME-405

UNIT – I

BROACHING

By

Dr.Yogesh Dewang
Assistant Professor
Lakshmi Narain College of Technology, Bhopal
Ph.D. (Mechanical Engineering) (MANIT,Bhopal)
M.Tech (Stress & Vibration Analysis) (MANIT,Bhopal)
B.E. (Mechanical Engineering) (RGPV,Bhopal)
E-Mail Id: yogesh_dewang@yahoo.co.in
Skype Id: yogesh.dewang1
09179829930
•Cutting tool used in this process is known as
“BROACH”.
•Broach is a tapered tool on which teeth are cut.
•Material is removed by pushing or pulling action of
tool.
•Material with C40 rockwell hardness can be
machined.
•Key ways, splines, clutch plates etc can be machined
by broaching.
Principle of working:

•Work piece is fixed on fixture and broach is pulled or pushed.

Sharp edges of broach penetrate into work piece and due to
shearing action plastic deformation of workpiece takes place and
metal removes in form of chips.
• Thickness of chip is approximately half the pitch. Chips are
collected in to chip space and it is removed when broach comes
out from workpiece.
• Constructional Features:
1)Work holding fixture
2)Broaching tool
3)Drive Mechanism
4)Supporting frame.
1) Work holding fixture
• Used to hold work piece in proper
position
• Some times it guides tools
• It is also used to rotate work
piece in cutting of helical gear.
• Three types of fixtures-Manual,
semi automatic, automatic.
• Manual fixtures are used for small
batches,
• Hydraulic and Pneumatic type
semi automatic or automatic
fixtures are used in mass
production
2) Broach Tool
Classification:
• According to type of cut: -External broach
-Internal broach
2) According to method of cutting: -Push broach
-Pull broach
3) According to shape: -Solid broach
-Inserted broach
-Progressive broach
4) According to application: -Keyway broach
-Spline broach
-Helical cut broach
2) Broach Tool
Classification:
Internal broach: Used to increase hole size and finishing
External broach: Used to make external shapes. Small segments are
arranged in row in one piece.
Push broach: It is pushed in work piece to remove material. It is having
small length to reduce possibility of bending of tool
Pull broach: Material is removed by pulling action of broach from work
piece.
Solid broach: It is made from single bar stock. It has high dimensional
accuracy. Entire broach is replaced in case of wear of teeth.
Inserted broach: It is made of tool holder and inserts of HSS, carbides
etc. Inserts are brazed on tool holder.
Progressive broach: It is used for wide surfaces. Two pairs of rough teeth
and finish teeth are used. Surface is machined in one pass.
Nomenclature of broach:
Nomenclature of broach:
Pull End: It is provided in pull broach to attach pulling
mechanism.
Front pilot: It guides broach in hole and also works as
rough no-go gauge.
Rear pilot: It determines size of finished hole.
Follower diameter: It is held in automatic machine in
order bring in original position.
Shank length: It is length to pass from work piece and
attach puller before roughing teeth engage with work
piece.
Nomenclature of broach:
Rough teeth: It removes major material.
Semi finish teeth: Provides smoothness while cutting
Finishing teeth: They are of same height. Provides
finishing to work piece.
Land: It is upper most portion of tooth.
Back off angle: Also known as clearance or relief angle.
It prevents rubbing of land. Angle is between 0.50 to 3o.
Face angle: Also known as hook angle. It can be
compared with rake angle of single point tool. Angle is
between 150 to 200.
Nomenclature of broach:
Tooth gullet: Chip space between two tooth of tool.
Pitch: Distance between same point on two successive
teeth.
Chip breaker:Prevents collection of chip
3) Drive Mechanism:
Mechanical(Screw & Nut), Hydraulic or Pneumatic
drives are used to provide reciprocating motion.
4) Supporting Frame:
Casted heavy part of machine which supports
various parts of machine.
Types of broaching machines
A) According to direction of broach travel.
1) Horizontal broaching machine
2) Vertical broaching machine
B) According to Method of operation.
1) Pull broaching machine
2) Push broaching machine
3) Surface broaching machine
4) Continuous broaching machine
C) According to Method of drive.
1) Mechanical Drive machine
2) Pneumatic drive machine
3) Hydraulic drive machine
D) According to type of operation.
1) External broaching machine
2) Internal broaching machine
1) Horizontal broaching
machine.
• Usually pull type.
• Used for internal and external
broaching.
• Bed is approximately double size
than broach stroke
• Ram is hydraulically operated.
• Used to make keyways, splines,
slots etc.
2)Vertical Broaching machine
• It can be push type or pull type.
• Broach is held vertically.
• 2,4,6 broaches can be operated at
time.
• Stroke height is limited upto 1500mm.
• Less space is required compared to
horizontal machine.
• Hydraulic or electromechanical drives
can be used.
• Preferable for mass production
3)Continuous broaching
machine
• Used for mass production of small
work pieces.
• Rotary or Horizontal type of
movement can be provided.
• In rotary machine, rotary table is
used. W/P is indexed and
broaching is done.
• In horizontal machine, conveyer
continuously moves and broach
remains steady.
Advantages of broaching:
1) High production rate.
2) Job is prepared in one stroke
3) High tool life
4) Internal and external machining can be done
5) 0.8micron finishing can be obtained
6) Interchangeability of components can be done due to tolerances
obtained in range.
7) Roughing and finishing can be done in single stroke
Limitations of broaching:
1) Costly tool
2) Not suitable for small batch.
3) Less amount of material is removed
4) Proper fixtures are required.
5) Strains are produced in w/p
6) Surfaces should be parallel to broach travel axis.