Name of the course: Mechanical Engineering (Production)

Name of the subject

MACHINE TOOLS
Group C-Chapter 11

Broaching Machine

Name of the topic: Broaching Machine

Name of faculty: Bappa Patra
Lecturer in Mechanical Engineering
Nazrul Centenary Polytechnic
 LEARNING OUTCOMES

 At the end of this lesson, the students would be able to:

(i) State the basic principle of broaching

(ii) Describe constructional features of broaching tools

(iii)Illustrate different broaching tools

(iv)Explain different types of broaching machines

(v) State the application, advantages and limitations of broaching.

 BROACHING MACHINE

Broaching is a machining process that uses a toothed

tool, called a broach, to remove material of desired
width and depth usually in one stroke.
Broaching process is divided into two processes mainly: -

i) Linear Broaching.
ii) Rotary Broaching.

i) Linear Broaching:
In this type of broaching, the broach is run linearly against the surface of the workpiece to effect the cut. Linear broaches are
used in a broaching machine.

ii) Rotary Broaching:

In this type of broaching, the broach is rotated and pressed into the workpiece to cut an axisymmetric shape. A rotary broach is
commonly is used in a lathe or screw machine.

In both linear and rotary broaching process, the cut is performed in only one pass which makes it very much efficient.
Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include
circular and non-circular holes, splines, keyways, and flat surfaces. Typical workpieces include small to medium-sized
castings, forgings, screw machine parts, and stampings. Even though broaches can be expensive, broaching is usually favoured
over other processes when used for high-quantity production runs.
Broaches are shaped similar to a saw, except the height of the teeth increases over the length of the tool. Moreover, the broach
contains three distinct sections: one for roughing, another for semi-finishing, and the final one for finishing.
 TYPES OF BROACHES
 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. Broaches can be broadly classified in
several aspects such as,

 (1) Pull type

 (2) Push type

 (3) Ordinary cut type

 (4) Progressive cut type

(5) Solid type

 (6) Sectional type

 (7) Modular type

 (8) Profile sharpened type

Based on cutting location broaching are divided into two types: -

i) Internal Broaching.

ii) External Broaching.

i) Internal Broaching: -

In internal broaching, the material is removed from the internal surface of the workpiece. It is also known as hole
broaching. For broaching internally, a metal, a pre-existing hole must be made first. It is mainly used to enlarge a hole or
resize it. Internal broaching also provides good finishing. In internal broaching, the broaching tool has teeth that become
larger successively. Internal broaching machines are automated, often CNC operated and are able to quickly and
efficiently produces a hole in metal parts and products.
 PULL TYPE BROACH TOOL

Pull type broach tool is commonly long in length because it is

pulled and tension is created in it while pulling. It has a
longer life than Push Type Broaching. It has a large number
of teeth and it provides a longer cut.
 PUSH TYPE BROACH TOOL

Push type broach tool is short in length than pull type broaching tool because it experiences compressive forces while it is
pushed.
It has fewer teeth than pull-type broach tool because chances of bending and getting broken is high as compressive forces
are applied to it.
It provides a shorter cut than pull type broach.

The parts of the push type broach tool are the same as parts of pull type broach tool but the size of teeth and other parts of
the broach tool is smaller than the tool of pull type broach.
 EXTERNAL BROACHING

 In external broaching, material is removed from the external

surface of the workpiece. It is also called surface broaching.
It is used to remove material from the surface of the tool,
keyway cutting and creating a slot. The teeth of the external
broach tool also increases progressively.

 External surface broaching competes with milling, shaping and

planning and, wherever feasible, outperforms those processes in
respect of productivity and product quality. External broaching
tools may be both pull and push type.
 PROFILE SHARPENED AND FORM RELIEVED TYPE
BROACHES

 Like milling cutters, broaches can also be 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.
 DETAILS OF BROACH CONSTRUCTION
Construction of internal broach

Parts of Pull-Type Broach Tool: -

1) Pull End:-
It is the handle of the pull broach tool which is used while pulling the broach tool.
2) Neck:-
The neck connects the pull end to the root diameter.
3) Shank:-
The part from the pull end to root diameter is a shank that is hold and pulled inside the machine. The length of the tool from pull end to root
diameter is known as shank length.
4) Teeth: -
Teeth are placed in the pull-type broach tool after the shank. The size of the teeth increases progressively from start to end.
The teeth are divided into three portions in pull type broach tool. These are: -
a) Cutting Teeth
The portion of teeth near the shank is called cutting teeth. These teeth are also known as roughing teeth.
The size of two consecutive teeth varies largely. The difference between their sizes are large. Cutting teeth will provide the maximum cut in the
workpiece and remove maximum material from the workpiece as compared to other portions of teeth.

b) Semi finishing teeth

After cutting teeth, there are semi-finishing teeth. The difference between sizes of two teeth in semi finishing teeth is large but less than cutting
teeth.
Semi finishing teeth are used for semi finishing. These teeth remove very less material from the workpiece as compared to semi finishing teeth.

c) Finishing Teeth
The last portion of teeth after the semi finishing teeth are known as finishing teeth.
These finishing teeth do not have variation in their sizes i.e all the finishing teeth are of nearly the same sizes.
Finishing teeth will provide finishing to the cut produced by the cutting and semi finishing teeth. So, these teeth are known as finishing teeth.

5) Rear Pilot
After the finishing teeth, rear pilot is present in the pull type broach tool. It is used to balance the broach tool and keep it in alignment.

6) Follower End and Retriever

They are present at end of the pull type broach tool. They both are supporting elements of the tool and supports the tool.
 CONSTRUCTION OF EXTERNAL BROACH

#Land
Land is present in the bottom of the teeth and it provides support to
the cutting edge.
#Rake
Rake is provided in each tooth of the external broaching tool. The
chip from the workpiece after the cutting process flow through this
rake.
# Clearance Angle
Clearance Angle is the angle of the land or bottom part of the tool
with the horizontal axis. It prevents friction between the teeth and
workpiece and only the cutting edge of teeth is in contact with the
workpiece while the cutting process.
#Depth
The height of each of t/*he teeth is known as depth.
# Pitch
The distance between the cutting edges of any two teeth is known as
pitch.
#Gullet radius
This radial space is present between two teeth through which the
chip flow and go outside after getting curled.
 BROACHING MACHINES & ITS
CLASSIFICATION
 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.

 Broaching machines are generally specified by

 ο Type; horizontal, vertical etc.

 ο Maximum stroke length

 ο Maximum working force (pull or push)

 ο Maximum cutting velocity possible

 ο Power

 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.
 HORIZONTAL BROACHING
MACHINE
 In case of horizontal broaching machine, movement of
broach is in horizontal direction. These machines are
normally designed for pull broaching, surface broaching,
continuous broaching and rotary broaching. These
machines are not so popular as the vertical broaching
machines.

 Horizontal broaching machines are capable of both

internal and external surfaces.
 In operation either workpiece is kept stationery and
broach is fed past or broach is kept stationery and
workpiece is fed past.
 This machine has bed similar to the lathe machine.
 VERTICAL PULL TYPE BROACHING MACHINE

 In case of vertical broaching machine movement of broach is in vertical direction.

These machines may have the stroke length more than 1.5 meter. Vertical
broaching machines can be designed for push broaching, pull down broaching,
pull-up broaching or surface broaching. Normally surface broaching is done by
vertical broaching machine.

 This type of machine is available for both pull up and pull-down type of
machine
 This machine is only used for internal broaching or hole broaching

 In this machine we can mount more than one broach.

 In the pull-down type, the workpiece is mounted on the table and the broach is
lowered to pass its front pilot through the workpiece.

 In the pull up type, the only difference is that the ram is provided at the top
which will carry the broach from bottom to top.
 CONTINUOUS BROACHING
MACHINE
 Continuous broaching machine is a different type of classification. These machines can be
horizontal or vertical type. The concept of continuous broaching machine is concerned
with continuity. This continuity of operation can be maintained by keeping the broach
stationary and moving workpiece through the tool (broach) to perform cutting. In case of
horizontal continuous broaching machines two sprockets, one on each side of the
machine, are maintained. On the sprockets, there is continuous travel of an endless chain
having a series of fixtures mounted on it. The broaches are rigidly hold on the machine in
horizontal position over the chain. Workpieces are loaded on the fixtures on one side of
the machine and unloaded on its over sides.

 This machine is available both in horizontal and vertical type

 In this machine the broach remains stationery while the workpiece moves continuously
past.
 In this machine the workpiece is fed past on the chain which is travelling continuously
with the help of sprockets on both the end.
 The chain has a fixture which will hold the workpiece.
 In this machine the workpiece is loaded on a side and unloaded on the other side.
 ROTARY BROACHING MACHINES

 Generally, a rotary broaching machine requires two important

tooling components a tool holds and a broach.
 The broach is mounted in the tool holder that facilitates it to
freely rotate. The tool holder is specially designed so that it can
hold the tool keeping its axis of rotation slightly inclined (1 to
20) to the axis of rotation of the workpiece.
 This small misalignment helps the broach in cutting.
 The cutting action is named as “wobbling” and the broach
mounted in this way is called “wobbling broach”.
 It is not necessary to use broaching machine in case of rotary
broaching. This can be done with the help of lathe machine.
 The required rotary motion to the broach can be given by the
chuck of the lathe.
 BROACHING FIXTURES

 Fixtures are used for providing an accurate pre-decided movement to broach with proper clamping action. Accuracy and
rigidity of fixture make the operation of broaching repeatable and fit for mass production.

 Functions of broaching fixture are summarized as given below:

 (a) Fixture holds the work piece accurately and rigidity and moves it to the exact cutting position.

 (b) Guide the movement of the broach in pre-decided manner relative to the work piece.

 (c) Fixture is also responsible to give feed motion to work piece after completion of the cut.
 BROACHING OPERATION – METHODS OF
BROACHING

Broaching Machine Operations

 Broaching is applied for machining various internal and external surfaces, for a round or irregular shaped holes from 6 to
100 mm in diameter, for external flat and contoured surfaces.
 Certain types of surfaces, for example, spline holes, broaching a key-way in a hole are machined at the present time only by
broaching due to the exceptional difficulties in machining such surfaces by other methods. Some operations are done in one
pass, but some operation arranged for repeated cuts to the design of the broach.

 The teeth of a gear or spline may be broached all together or one or a few at a time. A comparatively simple broach can be
made to cut one or a few tooth spaces. After one pass, the gear blank is indexed and more of its teeth are cut. Successive
passes are made until all the teeth are finished.
 BROACHING METHODS

 Following are the classification of broaching methods:

 Pull Broaching

 Push Broaching

 Surface Broaching

 Continuous Broaching
Pull Broaching
In the pull broaching the work is held fixed and the broach is pulled through the work. Usually, broaches are very long and are
held in a special head. Pull broaching method is used for internal broaching but it also used for some surface broaching.
Push Broaching
In the push broaching the work is fixed and the broach is pushed through the work. Hand and hydraulic arbor presses are
commonly used for push broaching. This method is used for sizing holes and cutting keyways.
Surface Broaching
In surface broaching either the work or the broaching tool moves across the other. This method has become an important means
of surface finishing. Many irregular or intricate shapes can be broached by surface broaching, but the tools must be specially
designed for each job.

Continuous Broaching

In continuous broaching the work is moved continuously and the broach us held stationary. The movement of work may be
either straight horizontal or circular. The continuous broaching method is mostly used for broaching a number of similar works
at the same time.
 APPLICATIONS OF BROACHING

 Broaching used for producing the variety of shapes, internal and external regular and irregular profiles

 The examples of components produced by broaching are as follows:

 Bearing caps
 Bearing bodies
 Cylinder blocks
 Connecting rods
 Gears and turbine
 Keyways
 Splines
 ADVANTAGES OF BROACHING

 Very high production rate (much higher than milling, planning, boring etc.)
 High dimensional and form accuracy and surface finish of the product. A tolerance of ±0.0075mm and a surface
finish about 0.8 microns (1 micron=0.001mm) can be easily obtained in broaching.

 Roughing and finishing in single stroke of the same cutter

 Needs only one motion (cutting), so design, construction, operation and control are simpler
 Extremely suitable and economic for mass production
 The broaching process is used for internal and external surface finishing.
 LIMITATIONS OF BROACHING

 Only through holes and surfaces can be machined

 Usable only for light cuts, i.e. low chip load
 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 the production volume is large
 Very large work-piece cannot be broached.
References:

1. A text book of Workshop Technology-Vol II (M/C Tool)- B. S. Raghuwanshi

2. http://www.mechanicalwalkins.com/broaching-types-of-boaching-and-different-broach-tools-with-diagra
m/
3. https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-26.pdf
4. https://learnmech.com/types-of-broaching-machine-classification-of-broaching-machine/
5. https://www.theengineerspost.com/broaching-machine/
6. Google images