THE DESIGN OF BROACHING MACHINE

UNDER SUPERVISION OF PROF.DR/ REFAAT EL_SHEIKH

ENG/ HEBA HOSSAM

BY/
Mohamed Amjad
Mohamed Amer
Mohamed Abd El_ Nassir

4TH YEAR
MECHANICAL DESIGN& PRODUCTION DEPT

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 Contents
❖ INTRODUCTION............................................................................................................. 3
❖ Types of broaching processes ............................................................................................. 4
❖ Types of broaching tools .................................................................................................... 5
❖ Geometry of broaching tool................................................................................................ 6
❖ Design of Cutting Tool....................................................................................................... 7
1) Nominal allowance: ........................................................................................................ 7
2) Calculate longitudinal chip space Area ............................................................................... 8
3)Calculating number of teeth ............................................................................................... 9
4)Calculate the cutting force:................................................................................................10
5)Working length of tool ......................................................................................................10
6)Material used for the tool ..................................................................................................10
7)Strength design.................................................................................................................11
8)Calculations of power........................................................................................................11
❖ Shapes Prepared by Internal Broaching.............................................................................12
❖ Product of Spline Broaching .............................................................................................12

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❖INTRODUCTION
Broaching is used for machining through holes of any cross-sectional shape,
straight and helical slots, external surfaces of various shape, and external and
internal toothed gears.

A broach is a multiple-tooth, and the motion of the broaching tool is primarily

along the axis of the hole. each tooth increases gradually from front to rear that
means that every tooth removes part of the material as it moves causing the hole
to increase as it imparts its shape to the hole.

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 ❖Types of broaching processes
The broach is usually secured in the main slide of the broaching machine and
travels with the slide.

A round broach travels along the axis of the hole being broached. Since the teeth is
gradually increase in size from the front to the rear end of the broach, each
successive tooth removes a layer of material, thereby increasing the size of the
hole.

If the force applied to the shank the broach is in tension called pull broaching.

If the force applied to the rear it’s called push broaching and it’s in compression.

To avoid buckling, a push broach should be shorter than a pull broach and it’s
length shouldn’t exceed 15 diameters.

Pull broaching

Push broaching

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❖Types of broaching tools

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❖Geometry of broaching tool
The relief angle is measured in a section coinciding with the direction of the
cutting motion. It’s selected independently of the work material and should ensure
good conditions of cutting by reducing the friction between the tooth flank and the
machined surface.

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❖Design of Cutting Tool

1) Nominal allowance:
𝑨𝒓𝒆𝒂 = 𝟎. 𝟎𝟎𝟓 ∗ 𝑫 + (𝟎.𝟏 − 𝟎. 𝟐)√𝑳

• D: diameter of workpiece

• L: length of workpiece

𝐀𝐫𝐞𝐚 = 𝟎. 𝟎𝟎𝟓 ∗ 𝟒𝟎 + ( 𝟎. 𝟏𝟓)√𝟐𝟎𝟎 = 𝟐. 𝟑𝟐 𝒎𝒎𝟐

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 • The table above used to find the value of Sz

• We will make straight spline so the cut per tooth Sz =0.06 mm

2) Calculate longitudinal chip space Area

𝑨𝒊 = 𝑳𝒔𝒛 𝐴𝑖 = 200 ∗ 0.06 = 𝟏𝟐 𝐦𝐦𝟐

So chip space area
𝑨 = 𝑲 𝑨𝒊
K is a constant= (3-6)
Then A = 5 ∗ 12 = 𝟔𝟎 𝐦𝐦𝟐

• From the table down we will take the area =62.7 𝐦𝐦𝟐
So
Broach pitch: t = 20 mm
Depth of chip space: h = 8.1 mm
Land width: f = 6.5 mm
Radius: r = 4.5 mm

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3)Calculating number of teeth
𝑨
𝒁𝒄 = + ( 𝟐 − 𝟒)
𝟐𝒔𝒛

2.32
𝑍𝑐 = + (3) = 𝟐𝟐 𝒕𝒐𝒐𝒕𝒉
2 ∗ 0.06

The number of teeth in contact with the workpiece at the same time

𝐋
𝐙𝐦𝐚𝐱 = 𝐭
+𝟏

200
Zmax = + 1 = 𝟏𝟏
20

Then take the number of finishing teeth = (4-8)

The total number of teeth = 22+ 7= 29tooth

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4)Calculate the cutting force:

The cutting force is given

𝐅𝐳 = 𝟓𝟎𝟎𝐊𝐠 = 𝟓𝟎𝟎𝟎𝐍
𝑭𝒛 𝟓𝟎𝟎
R= = = 𝟖𝑲𝒈/𝒎𝒎^𝟐
𝑨𝒐 𝟔𝟐.𝟕
From the table we take the max value for R is 25
So Rd<Rmax so the design safe

5)Working length of tool

• 𝐿𝑐 = 𝑍𝑐 × 𝑡 = 22 × 20 = 440𝑚𝑚
• 𝐿𝑓 = 𝑍𝑓 × 𝑡 = 7 × 20 = 140𝑚𝑚

6)Material used for the tool

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7)Strength design

• 𝐴𝑠𝑠𝑢𝑚𝑒 ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒 +

2 × 𝐴𝑏
• 𝐷 = 40 + 2 ∗ 2.32 = 44.64𝑚𝑚~45𝑚𝑚
• We will take D inner = D outer/1.5=30mm
45+30
• The average diameter = =37.5mm
2

• 𝛿𝑦 = 1000𝑀𝑝𝑎 𝑓𝑟𝑜𝑚 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑡𝑎𝑏𝑙𝑒 , 𝑡𝑎𝑘𝑒 𝐹. 𝑂. 𝑆 = 5

𝛿𝑦 1000
• 𝛿𝑎 = = = 200 𝑀𝑝𝑎 𝑤𝑒 𝑡𝑎𝑘𝑒 𝐹 = 500𝐾𝑔 =
𝐹.𝑂.𝑆 5

5𝐾𝑁
𝐹 5000
• 𝛿= = = 45.27𝑀𝑝𝑎 < 𝛿𝑎
𝐴 0.25𝜋×0.03752

• So the design is safe

8)Calculations of power
𝐯×𝐅𝐳
 𝐍=
𝟔𝟎×𝟏𝟎𝟐

 The speed is given:

 V=12m/min

 Then calculate the power

12×5000
 𝑁= = 𝟖𝑲𝑾
60 ×102

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❖Shapes Prepared by Internal Broaching

❖Product of Spline Broaching

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