Contents

7.1 lntroduction to Sawing Machines ....................................................................................................... 7.2

7.2 Classification of Sawing Machines .................................................................................................... 7.2
7.3 Saw Blades ......................................................................................................................................... 7.6
7.4 Advantage and Disadvantage And Application ofSawing ................................................................. 7.7
7.5 lntroduction to Broaching Machines .................................................................................................. 7.8
7.6 Broach Geometry / Elements of Broach............................................................................................. 7.8
7.7 Basic Broaching Process .................................................................................................................. 7.10
7.8 Types of Broach ............................................................................................................................... 7.10
7.9 Principle of Broaching ..................................................................................................................... 7.10
7.10 Types of Broaching Machines .......................................................................................................... 7.11
7.11 Horizontal Broaching Machine ........................................................................................................ 7.11
7.12 Vertical pull type Broach Machines ................................................................................................. 7.12
7.13 ContinuousBroach Machine ............................................................................................................. 7.12
7.14 Surface Broaching Machine ............................................................................................................. 7.14
7.15 key way broaching machine ............................................................................................................. 7.14
7.16 Advantage, Disadvantage Application of Broaching machine......................................................... 7.14
7.17 Broach Materials .............................................................................................................................. 7.16
7.18 References ........................................................................................................................................ 7.16
7.1 introduction to Sawing Machines
 In machining of metalworking jobs, the first step is to cut the stock to the desired length.
 Many parts of machines (of any type) are cut from round, square, flat or hexagonal bar stock or tubing.
 This cutting-off operation should be done in the shortest possible time with the desired quality.
 For this purpose, different sawing machines are used which are either power operated or manually operated.
 The cutting action in the power sawing process is performed by the action of a continuous series of single-
point cutting tools as they pass over the workpiece.
 The tool life (cutters or blades) is more because the cutting load is shared by individual teeth.

7.2 Classification of Sawing Machines

 Sawing machines are generally classified according to the type of motion used in the cutting action.
Following are the three general types which are commonly used:
1. Reciprocating saw
a. Manual hacksaw b. Manual hacksaw
2. Band saw
a. Vertical cut-off saw b. Horizontal cut-off saw
c. Combination cut-off saw d. Friction blade
3. Circular saw
a. Cold saw b. Steel friction disk

7.2.1 Manual or Hand Hacksaw

 A hacksaw is a common tool used for cuffing required lengths of bar stocks, rods, etc. in a workshop.
 Hacksaw consists of a metal frame, fitted with a wooden handle and carrying metal with wing-nut at the end
to hold and stretch the blade. Refer Fig. 7.1.

Fig.7.1 – manual or hand Hacksaw

 Generally, push-type blades i.e. those which cut in forward stroke are used. In these blades, teeth are away
from the operator.
 Proper care should be taken while fixing the blade in Saw and Broach ensure the direction of teeth.
 The blades in common use are usually 0.7 mm thick, 12.7 mm wide and.20 cm to 30 cm long.

7.2.2 Power Hack Saw

 In machining of metalworking jobs, the first step is to cut the stock to the required length.
 Many parts of the machines are cut from round, square, flat or hexagonal bar stock.
 This cutting-off operation should be done in the shortest possible time with the desired quality. For this
purpose, different sawing machines are used which are either power operated or manually operated.

Prof. Paras G. Vegada Department of Mechanical Engineering

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 Fig.7.2 – Power Hack Saw

 But power operated machines or power saw is most commonly used.

 A reciprocating power saw is shown in Fig. 7.2 which consists of following basic elements :
1. Base 2. Vice 3. Clamping mechanism
4. Hack saw frame 5. Driving head 6. Coolant arrangement
1. Base

 The base is the lowermost and rigid part of the power saw machine. It supports all other elements of the
machine.
2. Vice

 Vice or work holding jaws are used to hold the workpiece.

 One of the jaws is fixed and the other is moving with the help of the clamping mechanism.
 The movable jaw can be swivelled to 45̊ on either side for clamping of the workpiece of different sizes.
3. Clamping mechanism

 The movable jaw of the machine can be moved by using a screw and nut arrangement.
 For this purpose, the handle is provided in the machine.
4. Hack-saw frame

 The hack-saw is connected with the hack-saw frame.

 Hack-saw reciprocates with the hack-saw frame.
 During the forward or idle stroke, the frame is lifted up to make the blade clear of the workpiece.
5. Driving head

 The main driving motor is housed in the driving head'

 The driving head gives the reciprocating motion to the hack-saw frame.
 The hack-saw cuts the workpiece during the backward stroke and the forward stroke is an idle stroke
6. Coolant arrangement

 During the cutting operation, the coolant is supplied for dissipating the heat.
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  A sufficient amount of coolant is also required for efficient operation and longer life of the blade.
 The main body also consists of a coolant tank which is made in two parts.
 A slot is made in the bed, through which the used coolant falls into the sump and the swarf (waste material)
is collected in a separate tray.

7.2.3 Band Saw

 The band saw employs the continuous action of an endless high speed toothed blade.
 The advantages of a band saw over hacksaw are,
 Its cutting speed is twice of a hacksaw
 It can cut irregular curves in metals.
 Only the limitation is that its cost is more than the hacksaw.

7.2.3.1 Vertical Band Saw

 A vertical band saw machine is also known as contour machine. The main parts of the vertical band saw are
shown in Fig. 7.3.

Fig.7.3 – Vertical Band Saw

 In a band saw, a continuous saw blade or band runs over the rims of two wheels (upper and lower), one of
which drives the saw at the required cutting speed.
 The workpiece is mounted on the table between the two wheels.
 The band saw is never ideal during its motion. This continuous action makes the bandsaw more Productive.
 The workpiece may be fed in any direction on the table and the direction of feed is readily controlled and
changed while cutting is in the process to produce any required outline.
 Vertical band saw is used for the following purposes
 Cutting-off the sprues and risers from castings.
 Making dies or tools with contour internal shape,

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  Filing and polishing contours of a regular or irregular shape by substituting special file bands or abrasive
belts.
 Straight, internal or external and angular cutting is performed.

7.2.3.2 Horizontal Band Saw

 A horizontal band saw machine is also known as cut-off band saw machine. Refer Fig.7.4.
 It consists of a frame which carries driven and driver wheel. The driver wheel is connected to the motor or
prime mover.

Fig.7.4 – Horizontal band saw

 These two wheels are connected with the help of the saw band.
 To maintain the proper tension in the blade, a tension control mechanism is employed so as to run the blade
continuously on the wheel.
 The adjustable supports and guides are provided at the cutting area to support the band
 The cutting takes place due to the continuous running of the saw bands into the work
 Horizontal band saw has the flexibility of the power saw and continuous cutting action of the vertical band
saws. Hence, this machine is very efficient.

7.2.4 Circular Saw

 The circular sawing machine is also known as cold sawing machine which is widely used for the cut-off
operation.
 These machines differ from a hacksaw or band saw in respect of the cutter or blade.

Fig.7.5 – Circular Saw

Prof. Paras G. Vegada Department of Mechanical Engineering

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  Circular sawing machines employ a toothed circular disk cutter as shown in Fig. 7.5 which is similar to the
slitting cutter used on milling machines.
 The circular saw blades are fairly large in diameter (250 to 400 mm) and operate at low speeds.
 The blade may have teeth either cut on its periphery or may have inserted teeth or removable segments that
may contain several teeth.
 The main advantage of segmented teeth saw is that the disk can be made of less expensive steel and the teeth
can be made up of high-speed steel or tungsten carbide.
 During cutting operation, the saw is fed into the workpiece which is positively clamped by mechanical or
hydraulic means,
 a circular saw is generally used for cutting pieces of much bigger diameter.
 A cutting fluid is recommended during cutting of all metals except cast iron.

7.3 Saw Blades

 Saw blades are the cutters used on different sawing machines for cut-off and other operations.
 Saw blades are generally made from carbon steel, high-speed steel or tungsten carbide.
 Fig. 7.6 shows the main parts of the band tool.

Fig.7.6 – Saw Blades

 The face forms the main bearing surface against which the chip strikes.
 Gullet helps to remove the chips from the cut.
 The pitch of saw blades is the distance between the tops of two adjacent teeth.
 Tooth spacing generally controls the size of the teeth.
 The space between the teeth tends to be large and this spacing must be sufficient to contain the chip that is
formed without crowding.
 The tooth spacing should be such that, at least two teeth bear on the workpiece at all times.
The setting of saw teeth
 Tooth set generally refers to the type of tooth construction on a saw'
 To provide ample clearance for the blade during cutting the teeth are set to cut a slot slightly wider than the
thickness of the blade.
 This is done by bending the teeth slightly to the left or right side as shown inFig.7.7.

Prof. Paras G. Vegada Department of Mechanical Engineering

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 (a)

(b)

(c)
Fig.7.7 – Straight set

 Three types of commonly used tooth set are as follows :

a. Straight set or alternate set: It is used for cutting brass, copper and plastic. Refer Fig.7.7 (a).
b. Racker set: It is used for steel and iron cutting. Refer Fig. 7.7 (b).
c. Waveset: It is used for cutting tubes and light sheets of metal. Refer Fig. 7.7 (c),

7.4 Advantage and Disadvantage And Application of sawing

Advantages
 Tool life of the cutters or blades is increased due to the sharing of the wear in the teeth.
 The tooling cost is less.
 It ensures the fine finishing of the material.
 Unskilled or semi-skilled labor is required.
Disadvantages
 It can only cut straight lines or tight curves.
 It requires long cutting, preparation, and maintenance time.
Applications
 Different rolled or extruded shapes, tubing or flat plates stock, etc., are cut by power hacksawing or circular
sawing up to the desired length.
 It is used to remove unwanted or excess flash from the pressed steer parts.

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  It is used to remove gates, sprues, runners and risers from the different castings. o It is used to produce a
forging prototype for the design evaluation process. It is also used to produce cam profiles, parts of dies,
fixtures, etc.

7.5 introduction to Broaching Machines

 Broaching is a machining operation in which a tool used is called Broach having a series of cutting teeth.
 Broach is either pulled or pushed with the help of the broaching machine on the workpiece surface.
 Each tooth of a broach (tool) takes a small cut through the surface of the metal. Both external and internal
surfaces may be cut with the help of broaching.
 When the internal surface is machined, it is called internal or holes broaching and when the external surface
is machined, it is called external or surface broaching.
 Generally, the cutting operation is done by the first and intermediate teeth whereas finishing operation is
done by the last few teeth of the broach.
 Abroach is capable of removing material as deep as 6 mm in one stroke.
 Ferrous materials with a hardness up to RC.45 can be machined easily by broaching. Parts produced by
broaching have a good surface finish and dimensional accuracy.

7.6 Broach Geometry / Elements of Broach

 Fig. 7.8 (b) shows the details of pull-type internal broach for producing a cylindrical hole
 The broach is gripped at the shank end by the puller. Before the teeth, the front pilot enters into the hole to
keep proper alignment
 Broach consists of three sets of cutting teeth; The first set is called as roughing teeth,which does most of the
cutting operation.
 The second set is semi-finishing teeth, which removes less stock as compared to the first set. The size of the
second set is a little larger than the first set.
 The third set is used for finishing operation hence called finishing teeth, but the size of finishing teeth does
not vary. Finishing teeth removes a very small amount of material which is almost negligible.
 Fig. 7 .8 (a) shows the details of broach teeth, The principal elements of a common type of broach are as
follows :

(a) Broach teeth detail

Prof. Paras G. Vegada Department of Mechanical Engineering

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 (b) Broach term
Fig.7.8 – Broach geometry

1. Pull end
 The end of the pull broach, which contains shank, is the pull end. The broaching machines puller head grip
this end of a broach.
2. Front pilot
 It guides the broach into the hole and keeps it concentric with the latter. It helps in starting a straight cut.
3. Rear pilot
 Its size and shape confirms to those of the finished hole and provides support to the broach after the cutting
process is over.
4. Land
 It is the extreme top part of the tooth and it is normally ground slightly to provide clearance.
5. Tooth gullet
 It is also known as chip space. It provides space for the chips to curl and escape. The too-small space spoil
the whole surface as the chips will rub against it,
6. Pitch
 The linear distance measured between the cutting edge of one tooth and the corresponding point on the next
tooth is called pitch. But it is not the same for all the teeth of the broach.
 It is different for the three sets of teeth i.e. roughing, semi-finishing and finishing teeth.
7. Back off angle
 It is also known as a clearance angle and is ground on the land to provide relief.
 Its value normally varies from 0.5°to 3°, values from 1.5°to 2° being very common. For finishing teeth, no
clearance is provided.
8. Hook or rake angle
 It is also known as a face angle. It is similar to the rake angle provided on a single point too1.
 It depends upon the material to be cut and varies from 3° to 15°, the most common value is in between 12°
to 15°.
9. Hook radius
 It is the radius contained by the bottom of the gullet. It should have a very polished and smooth surface so as
to prevent the sticking of chips in the gullet.

Prof. Paras G. Vegada Department of Mechanical Engineering

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7.7 Basic Broaching Process
 As seen in the previous article, a broach is a tapered bar on which teeth are cut so as produce a desired contour
in the workpiece in a single pass of the broach.
 Fig. 7.9 shows the basic broaching process in which the workpiece to be internal must be provided with a
straight hole through which the broach is pushed or pulled.

Fig.7.9 – Broaching Process

 This hole is just large enough to permit the front pilot section of the broach to enter freely.
 As the broach advances through the part, cuffing starts gradually and as each succeeding tooth engages the
work, it removes a small amount of metal.

7.8 Types of Broach

1. A large variety of broaches is used in the industries. They are categorized as follows :

1. Based on the method of operation

a. Push type broach b. pull-type broach
2. Based on the kind of operation performed
a. Internal broach b. External broach
3. Based on construction
a. Solid broach d. Inserted tooth broach
b. Built-up broach e. Progressive cut broach
c. Rotor cut broach f. Overlapping tooth broach
4. Based on the use
a. Single-purpose broach b. Multi-purpose broach
5. Based on functions
a. Keyway Broach e. Roughing broach
b. Surface broach f. Rifling broach
c. Spline broach g. Spiral broach
d. Burnishing broach h. Serration broach

7.9 Principle of Broaching

 The broaching operation involves the use of mufti-tooth cutter called as the broach
 The broach teeth are so designed that the height of the following cutting tooth is slightly more equal to feed
per tooth than that of the preceding tooth.
 When the broach feed in line, metal is cut several successive layers with the help of broach
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  The thickness of each layer is the same and called feed per tooth and the sum of thicknesses of all the layers
is called depth of cut.
 Fig 7.10 (a) shows push-type broach which is used for machining of the external surface and Fig'7 .10 (b)
shows pull type broach which is used for machining of internal surface.
 During the process either broach is kept stationary and work is fed or work pies are kept stationary and a
broach is fed
 The surface produced by broaching carries an inverse profile as that of a broach used for the operation.

7.10 Types of Broaching Machines

 There are different types of broaching machines used in the industries corresponding to different applications.
Broaching machines are available in different sizes with different capacities. Broaching machines are Based
on power employed:
1. Based on power employed
a. Manually operated b. Manually operated
2. Based on the direction of movement of the broach
a. Horizontal b. Vertical pull up and pull down
3. Based on cutting
a. Pull type c. Push type
b. Push type
4. Based on the type of drive
a. Mechanical drive b. Hydraulic drive
5. Based on the number of pull heads
a. Single pull head b. Multiple pull head

7.11 Horizontal Broaching Machine

Construction and working:
 Horizontal broaching machines are applicable for machining external of both internal and external surfaces'
Fig' 7.10 (a) and (b) shows the principle of operation of broaching for internal and external machining.
 In operation either workpiece is kept stationary and, the broach is fed past on the workpiece or broach is kept
stationary and the workpiece is fed past on the broach.
 Horizontal broaching machines have a bed similar to the lathe machine and the broach is moves like a
tailstock on the bed ways.
 Horizontal internal broaching machines range from 2 to 60tones and stroke up to 3 m, whereas horizontal
extremely or surface broaching is available up to 100 tones and stroke up to 9 m.
 Horizontal internal broaching are generally used for producing internal splines in the boss of gear

(a) A push-type broach in use for machining external surface

Prof. Paras G. Vegada Department of Mechanical Engineering

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 (b) A pull-type broach in use for machining internal surface
Fig.7.10 – Principle of Broaching

7.12 Vertical Pull-Type Broach Machines

Construction and working:

Fig.7.11 – Vertical pull-type Broach Machines

 Vertical pull-type machines are available in two types i.e. pull up and pull down the type of machines.
 Both types are used for internal or hole broaching.
 The main advantage of this type of machine is that more than one broach can be mounted easily.
 In pull-down type, the workpiece is mounted on the table and broach is lowered to pass its front pilot through
the workpiece.
 This pilot is held by the pulling head attached at the top of the ram, which is enclosed in the bed.
 Broach is pull down with the help of ram and the desired hole is produced in the workpiece.
 In pull up type, the only difference is that ram is provided at the top which carries the pulling head at the
bottom.
 Fig 7.11 shows the principle of pull, down the type of broaching machine.

7.13 ContinuousBroach Machine

Construction and working:
 These types of machines are available both in horizontal as well as vertical type.

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 Fig.7.12 – Working principle of horizontal Continuous Broach Machine

 The main difference between other types of machines and horizontal continuous type machines is that the
broach remains stationary while the workpiece moves continue the type of past it to perform the cutting.
 The horizontal continuous machine consists of two sprockets one on each side of the machine, on which
endless chain continuously travels.
 A series of fixtures are mounted on this chain to travel along with it.
 On the machine, the broaches are rigidly held in a horizontal position and workpieces are loaded and
unloaded on either side of the machine on the fixtures.
 The principle of operation of a horizontal continuous broaching machine is as shown in fig 7.12

7.13.1 Rotary Table Broaching Machines

 Rotary table broaching machine is a useful type of continuous broaching machine.
 In this machine, a table is provided which continuously rotates about a vertical axis.
 On this table, the fixtures are mounted and broach is held rigidly in a broach holder above the table.
 The shape of a broach is similar to that of a rotary table and workpieces are loaded in the fixtures as shown
in Fig. 7.13.

Fig.7.13 – Working principle of rotary table horizontal continues

broaching machine

 As the table rotates machining of workpieces is done and new workpieces are loaded again.
 Thus, the cycle of loading, broaching, unloading and reloading is continuous without any break

Prof. Paras G. Vegada Department of Mechanical Engineering

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7.14 Surface Broaching Machine
 In surface broaching machines, either workpiece or broach moves across each other.
 The process of broaching an external work surface is known as surface broaching.
 These machines are generally vertical and hydraulically operated.
 Surface broaching machines are another alternative to the milling machine and hence in these machines,
fixtures are also used. Refer Fig.7.14.

Fig.7.14 – Surface broaching

 During operation, the broaching surface must be rigidly mounted and the workpiece must be solidly
supported as it passes the broaching section.
 These machines are used for large quantities of work and quite large, relatively flat surfaces.

7.15 keyway broaching machine

Construction and working:
 Fig. 7.15 shows the keyway broach with its adapter which guides the broach as well as does the work of
holding and locating the workpiece.

Fig.7.15 – Keyway broaching machine

 This is the simplest type of broaching machines and can be used for general purpose.
 If multiple keyways or splines are to be cut, a single broach can be used with the workpiece and indexed
after each cut.
 Broaching internal keyways is the oldest method.

7.16 Advantage, Disadvantage Application of Broaching machine

Advantages
 It is a faster process than other operations.
 The high rate of production is obtained with more accuracy and better surface finish.
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 Broach has a longer life than other tools.
 The tool cost per piece is low.
 Broach alone can perform roughing and finishing operations.
 Cutting fluid is easily and effectively applied to other operations.
 Interchangeable components can be produced at a faster rate.
 A better surface finish is obtained.
 A high skilled operator is not required.
Limitations
 To produce different shapes and sizes different broaches are required. o In the broaching process, all jobs
need a fixture, which is not economical.
 The sharpening of the broach is difficult and expensive.
 All types of surfaces cannot be machined.
 As cutting forces involved in the process are more, hence light and delicate jobs can not be broached.
 With the help of broaching, it is difficult to produce blind holes.
 The initial cost of a broach (tool) and broaching machine is very high, this leads to higher production costs.
Applications
 Broaching is used for producing a variety of shapes, internal and external, regular and irregular profiles. The
shapes which are difficult to produce by other operations can be easily produced by broaching.

Typical examples of components produced by broaching are as follows :

a. Bearing Caps
b. Bearing bodies
c. Cylinder blocks
d. Connecting rods
e. Cylinder heads
f. Crankcase
g. Sprockets for chain drive
h. Gears and turbine blades
i. Aircraft engine parts, etc. (Refer Fig. 7.16)

Fig.7.16 – Representative shape produce through internal broaching

Prof. Paras G. Vegada Department of Mechanical Engineering

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7.17 Broach Materials
 When broaches are used for light-duty work, then it is made of high carbon steel.
 For high production work and satisfactory performance, broaches are made up of HighSpeed Steel (H.S.S.).
 H.S.S. broach has a higher life and it gives a good surface finish.
 For hard rubber and cast iron material broach, teeth are tipped with sintered carbide.

7.18 References
1. Hajra & Choudhari. “Element of Workshop Technology Vol. II” Media Promoters and Pvt. Ltd
2. B.S.Raghuvanshi “A Course in Workshop technology Vol. II” Dhanpat Rai & Co,
3. R. K. Jain.”Production Technology” Khanna Publications

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