31-Jul-21

Today’s topic:
Broaching

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Broaching
Broaching is a fast machining process using a special tool made up of a
series of cutting edges, which are gradually increasing in size.
It is best suited for mass production and can produce accurate plane or
formed shapes on internal or external surfaces.
The metal is removed by the successive action of a number of teeth. One
pass of the broach over the work surface completes the machining
operation.
Broaching can produce parts with very good surface finish and
dimensional accuracy.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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 31-Jul-21

Principle of Broaching
In external broaching, the broach is pushed or pulled over an external flat
surface of a stationary workpiece.
In internal broaching, the broach is pushed or pulled through the hole in the
stationary workpiece.
In certain machines, the broach is held stationary and the workpiece
translates over the broach.
No separate feed is required, as the feeding action is in-built in the teeth
form. Each successive tooth is a little higher than the one preceding it.
Therefore each tooth removes a layer of workpiece material.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Principle of Broaching..
The first few teeth on broach are low to permit the small end of the tool to be passed
through work.
Intermediate teeth removes the most of the metal.
The last few teeth finish the surface to size.
Machining operation completes in one pass of the broach.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Classification of Broaching
According to the method of operation broaching is classified as
follows:
Pull broaching- the broach is pulled through stationary work
Push broaching - the broach is pushed through stationary work
Surface broaching - the broach moves across the work or vice versa
Continuous broaching - the work is moved continuosly against
stationary broaches.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Applications of Broaching
The operation was originally developed for machining small, internal
surfaces such as key way in a small diameter which is relatively
difficult for slotter. It is widely used in present day industry for
machining a large variety of jobs which were formerly milled or
shaped.
Internal broaching is used for machining and sizing of round holes,
square, hexagonal and many other shapes of holes. Internal keyways,
splines and gears are easily produced by broaching. External or
surface broaching is increasingly used in mass production as an
alternative to milling.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Advantages of Broaching
fast and simple process does not require a highly skilled
operator
high degree of accuracy and finish
cutting force acts in the clamping
any shape of profile can be easily
direction
machined
cutting fluids can be applied more
machining process is completed with easily and effectively
in one stroke of broach
economical for mass production of
life of tool is high
components
cutting temperature and tool wear is
low

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Limitations of Broaching
not economical for small quantity productions
cost of broach is high
tool grinding is difficult and expensive
not suitable to machine a surface having obstruction
the work must be strong enough to withstand cutting forces
very light and delicate jobs cannot be broached easily
cost of broaching machine is high
large amounts of metal cannot be removed by broaching

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Broaching Tool - internal pull broach

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Broaching Tool -push broach

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

5
 31-Jul-21

Broaching Tool
Broaching tool or broach is made up of a series of cutting edges
which are generally increasing in size along its length. Its length
depends on the amount of metal removal, length of stroke, amount
of accuracy and the degree of finish.
Three types of teeth are provided on broach tool. They are:
roughening teeth
semi-finishing teeth and
finishing teeth
The first roughening tooth is the smallest tooth on the broach.
SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Broaching Tool..
Rough teeth are designed to cut more metal. The next portion has
semi-finished teeth which are progressively increasing in size up to
and including the first finishing tooth. Finishing teeth are designed for
lighter cuts and last few finishing teeth are made of same size to
obtain high degree of accuracy and surface finish. In some broaches,
last few teeth edges are rounded for burnishing action.
Pull end is designed to permit engagement of broach with the
broaching machine by using puller head. Front pilot keeps the broach
in the centre of the hole before cutting. The most of the stock is
removed by roughening and semi finishing teeth and the hole is
finished to required shape by finishing teeth.
SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

6
 31-Jul-21

Broaching Tool....
Rear pilot and follower rest supports the broach after the last tooth
leaves the hole.
A push broach is made short to prevent bending under compressive
load. It is designed to push through the workpiece for machining. It is
generally used for sizing the holes.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE