UNIT - IV ABRASIVE PROCESS, SAWING, BROACHING & GEAR CUTTING

4.22 BROACHING MACHINES

4.22.1 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 work piece in the machine.

Planning tool - work motions.

Selection of the levels of the process parameters and their setting.

Conducting machining by the broach.

4.22.2 Selection of broach and broaching machine

There are various types of broaches available. The appropriate one has to be selected based on:

Type of the 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.

4.22.3 Function of broaching machines

The basic function of a broaching machine is to provide a precise linear motion of the tool past a
stationary work position. There are two principal modifications of the broaching machines, horizontal,
and vertical. The former are suitable for broaching of relatively long and small diameter holes, while the
later are used for short lengths and large diameters.
The unique characteristics of broaching operation are:

For producing any surface, the form of the tool (broach) always provides the Generatrix and the
cutting motion (of the broach relative to the job surface) provides the 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.

4.22.4 Specification of broaching machines

Broaching machines are generally specified by:

Type; horizontal, vertical etc.

Maximum stroke length.

Maximum working forces (pull or push).

Maximum cutting velocity possible.

Type of drive - Electro-Mechanical, Hydraulic etc.

Power rating of electrical motor.

Floor space required.
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.
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4.22.5 Classification of broaching machines

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.
According to the type of drive

Mechanical drive.

Hydraulic drive.

4.23 PUSH BROACHING MACHINES

In these machines the broach movement is guided by a ram. These machines are simple, since the
broach only needs to be pushed through the component for cutting and then retracted. The work piece is
fixed into a boring fixture on the table. Even simple arbor presses can be used for push broaching.

4.23.1 Push down type vertical surface broaching machine

Fig. 4.60 Push down type vertical surface broaching machine

Fig. 4.60 shows the push down type vertical surface broaching machine. It consists of a box
shape column, slide and drive mechanism. Broach is mounted on the slide which is hydraulically
operated and accurately guided on the column ways. Slide with the broach travels at various speeds. The
slide is provided with quick return mechanism. The worktable is mounted on the base in front of the
column. The fixture is clamped to the table. The work piece is held in the fixture.
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After advancing the table to the broaching position, it is clamped and the slide with the broach
travel downwards for machining the workpiece. Then the table recedes to load a new work piece and the
slide returns to its upper position. The same cycle is then repeated.
Vertical broaching machines occupy less floor space and are more rigid as the ram is supported
by the base. They are mostly used for external or surface broaching though internal broaching is also
possible and occasionally done.

4.24 PULL BROACHING MACHINES

These machines consist of a work holding mechanism, and a broach pulling mechanism along
with a broach elevator to help in the removal and threading of the broach through the work piece. The
work piece is mounted in the broaching fixture and the broach is inserted through the hole present in the
work piece.
Then the broach is pulled through the work piece completely and the work piece is then removed
from the table. Afterwards the broach is brought back to the starting point before a new work piece is
located on the table. The same cycle is then repeated.

4.24.1 Pull type horizontal internal broaching machine

Fig. 4.61 Pull type horizontal internal broaching machine

Fig. 4.61 shows the pull type horizontal internal broaching machine. This machine has a box
type bed. The length of bed is twice the length of stroke. Most of the modern horizontal broaching
machines are provided with hydraulic or electric drive. It is housed in the bed. The job is located in the
adopter. The adopter is fitted in the front vertical face of the machine. The small end of the broach is
inserted through the hole of the job and connected to the pulling head.
The pulling head is mounted in the front end of the ram. The ram is connected to the hydraulic
drive mechanism. The rear end of the broach is supported by a guide. The broach is moved along the
guide ways. It is used for small and medium sized works. It is used for machining keyways, splines,
serrations, internal gears, etc.
Horizontal broaching machines 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 occupy large floor space.

4.24.2 Pull down type vertical internal broaching machine

This machine has an elevator at the top. The pulling mechanism is enclosed in the base of the
machine. The workpiece is mounted on the table by means of fixture. The tail end of the broach is
gripped in the elevator. The broach is lowered through the work piece.

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The broach is automatically engaged by the pulling mechanism and is pulled down through the
job. After the operation is completed, the broach is raised and gripped by the elevator. The elevator
returns to its initial position. This is illustrated in Fig. 4.62 (a).

4.24.2 Pull up type vertical internal broaching machine

In this type, the ram slides on the vertical column of the machine. The ram carries the pulling
head at its bottom. The pulling mechanism is above the worktable and the broach is in the base of the
machine. The broach enters the job held against the underside of the table and is pulled upward. At the
end of the operation, the work is free and falls down into a container. This is illustrated in Fig. 4.62 (b).

Fig. 4.62 Vertical internal broaching operation (a) pull down type (b) pull up type

4.25 SURFACE BROACHING MACHINES

In horizontal surface broaching machines, the broach is pulled over the top surface of the work
piece held in the fixture on the worktable as shown in Fig. 4.63. The cutting speed ranges from 3 to 12
mpm with a return speed up to 30 mpm. The construction and working principle of horizontal surface
broaching machine is similar to that of pull type horizontal internal broaching machine.
In vertical surface broaching machines, the work piece is held in the fixture while the surface
broach is reciprocated with the ram on the vertical guide ways on the column as shown in Fig. 4.64.
Surface broaching is relatively simple since the broach can be continuously held and then it will carry
out only a reciprocating action. The construction and working principle of vertical surface broaching
machine is already discussed in the article no. 4.23.1 at page no.
Instead of using simple broach some times the progressive cut type broach with the teeth
segments distributed into the three areas as shown in Fig. 4.56 (b) is used in surface broaching. The
progressive action reduces the maximum broaching force, but results in a longer broach.

Fig. 4.63 Horizontal surface broaching machine Fig. 4.64 Vertical surface broaching machine

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4.26 CONTINUOUS BROACHING MACHINES

These broaching machines are also known as high production broaching machines. The
reciprocation of the broach always involves an unproductive return stroke, which is eliminated in a
continuous surface broaching machine. These machines are used for fast production of large number of
pieces by surface broaching.

4.26.1 Horizontal continuous broaching machine

In this the small work pieces are mounted on the broaching fixtures which are in turn fixed to an
endless chain continuously moving in between two sprockets. Broaches which are normally stationary
are kept above the work pieces. The work pieces are pushed past the stationary broaches by means of the
conveyor for cutting. The work pieces are loaded and unloaded onto the conveyor manually or
automatically. This is illustrated in Fig. 4.65 (a).

Fig. 4.65 Continuous broaching machine (a) Horizontal type (b) and (c) Rotary type

4.26.2 Rotary continuous broaching machine

Type I: This machine has a rotary table and a vertical column. The vertical column has a
guide way. An arm is fixed in the vertical column and it moves up and down in the guide way. Work
pieces are clamped in the fixtures horizontally above the work table. The broach is fixed underside of the
arm. Now the work table is rotated and the broaching operation is carried out. Depth of cut is given by
moving the work table in upward direction. This is illustrated in Fig. 4.65 (b).

Type II: This machine has a ring shaped rotating work table. Work pieces are clamped in
the fixtures in the inner periphery of the work table. The stationary broaches are fixed in the outer
periphery of the vertical column located inside the work table. Now the table is rotated and the broaching
operation is carried out. This is illustrated in Fig. 4.65 (c).

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.

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