WORKSHEET NO.

11
Finishing Processes—Reaming, Broaching, and Lapping

Name: RELATADO, VAN BEAVER Rating:

Course & Year: BSME-2 Date:

I. REVIEW QUESTIONS

Hand Reamers
1. What is the purpose of a hand reamer?
A reamer is a cutting tool that is used to open the size of an existing hole by a small
amount. A reamer will leave a smoother finish and a more precise size than a drill. Hand
reaming, or reaming a hole without coolant or oil will result in an oversized hole and a rougher
finish.

2. Describe and state the purpose of:

a. The solid hand reamer: Hand reamers are primarily used for assembly
work to make parts fit better. Their main feature is a long taper lead.
This ensures good guidance in the hole and prevents canting.

b. The expansion hand reamer: Hand Expansion Reamers are adjustable,

multi-fluted end cutting tools used to slightly enlarge previously
formed holes to a precise diameter with a smoother finish.

c. The taper finishing reamer: Multi-fluted, end cutting tools used to resize
and clean up previously formed holes to suit standard Morse Tapered
shanks. Suitable for reaming Morse taper sockets in a variety of normal
ferrous and non-ferrous materials.

3. How much metal should be removed with a hand reamer?

They should never remove more than 0.001" to 0.005" of material. Hand reamers are
available from 1/8" to over 2G in diameter and are generally made of carbon steel or high-speed
steel.

4. List four important precautions to be observed while reaming.

= Reamer Feeds and Speeds: Feeds and Speeds for machine reaming may vary
considerably depending in part on the material to be reamed, the type of machine, and
the required finish and accuracy.
= Alignment: In the ideal reaming job, the spindle, reamer, bushing, and hole to be
machined are all in perfect alignment.
= Chatter: The presence of chatter while reaming has a very bad effect on reamer life
and on the finish in the hole.

Broaching:

5. Define Broaching = a machining process that uses a toothed tool to

remove material in a consistent and accurate way.
6. Describe the cutting action of a broach. = Broaching is a machining
process that uses a toothed tool to remove material in a consistent and
accurate way. There are two types of broaching services, linear and
rotary, which are used to produce different kinds of machining finishes,
but in either case, production broaching is typically only used for
precision applications and high-quantity production.
 7. State three advantages of broaching.
= High production rate and low cycle. Broaching operation is faster than other metal
cutting operation. Then the price per piece will be low for broaching.
= Many operations replaced by broaching. A single stroke of broach can do both rough
cutting and finishing operations.
= The cutting force on workpiece act in the clamping direction, it assists in holding/
clamping of workpiece firmly in position.
8. Briefly describe the procedure for broaching a keyway on an arbor press.
Step 1: Tools and Materials
Tools:
= Broach Kit, including a broach, shims (as needed) and the appropriate
bushing.
= Arbor or Hydraulic Pres
Materials:
= Cutting Oil, my favorite is Tap Magic.

Step 2: Setting Up
= This is a small broach in soft material, so I can easily use the 3 ton arbor press. If you're
broaching a tougher material and/or a larger broach, you'll need a hydraulic press, as large
broaches can require thousands of pound of pressure to cut. Also, larger broaches are much
longer and often do not fit in an arbor press.

Step 3: Broaching
= Align the part with the gap in the press and ensure the broach is straight up and down. Then
apply even pressure, ensuring that the part is not tilting or rocking off the arbor press work
surface. In aluminum it requires little effort. Be prepared to catch the broach as it reaches the
end of its stroke- it may fall out. If the broach remains stuck in the part, use a small punch or
piece of stock to press it all the way out. Do not strike the broach, as you can mushroom the
end (sometimes imperceptibly) and cause yourself a big headache. Only press a broach.

Step 4: Resetting & Test Fitting

= With the broach removed, use a chip brush to remove the swarf from the broach. It's
important to clean these chips before broaching another keyway. Failure to do so can result in
the broach jamming in the bore.

Now, we can take a key and test fit the freshly broached pulley with a shaft. It's a perfect fit.
Often times I purchased shafts that already have the keyway machined in them. They are
available from McMaster Carr.

Lapping:

9. State three reasons for lapping.

= To produce a fine surface finish.
= To produce sealing surfaces.
= To produce sharp cutting edges.
10. What abrasives are generally used for lapping?
= There are four basic types of abrasives that are used in lapping and polishing
processes: silicon carbide (SiC), aluminum oxide or alumina (Al2O3), boron carbide
(B4C), and diamond (C). All of these abrasives have distinct properties and are used
for different materials and applications.
11. Why must the lap be softer than the workpiece?
= Because the lapping is a machining process of removing minute quantities of metal
from the surface which should be usually flat, smooth and accurate to size. Lap’s are
also used to finish holes, flat surfaces and outer surface of cylinders.

12. Explain the procedure for charging a flat lapping plate.

= Lapping is used to describe a number of various surface finishing operations where
loose abrasive powders are used as the grinding agent at normally low speeds. It is a
process reserved for products that demand very tight tolerances of flatness,
parallelism, thickness or finish.

13. Briefly describe the process of lapping a flat surface.

14. How are internal laps charged?

II. Draw the following:

1. Types of Hand Reamers

a. Solid hand reamer
b. Expansion hand reamer
c. Adjustable hand reamer
d. Taper reamer
e. Roughing reamer
f. Finishing taper reamer

2. Types of Laps
a. Flat laps
b. Internal Laps
c. External Laps