8 Broaching

Broaching
ME 202
Manufacturing
Technologies
Broaching
Broaching
Broaching is a unique machining process in which chips

are removed by a number of successive teeth
increasing in size, built on a long tool named broach.
Roughing, semifinishing, and finishing teeth, consequently
the related processes are combined in a single tool.
The profile of the machined surface is the inverse of the
profile of the broach.
The cutting action is performed in a fixed path, and with
one stroke of the broach the process is completed.
Broaching
ME 202 Manufacturing Technologies 2
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Broaching
Broaching
Broaching
Broaching
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Broaching
Broaching speeds are relatively low, seldom exceeding 15
m/min.
However, because a surface usually is completed in a
single stroke, the productivity is high.
A complete cycle usually requires only from 5 to 30
seconds, with most of that time being taken up by the
return stroke.
Broaching
Properties of Broaching
1. Simple and rapid way of machining,
2. Produces better accuracy and finish than milling and
reaming.
3. Suitable for mass production where the high production
rate justifies the cost of the expensive tool.
4. Either a special broach must be designed and
manufactured for each job, or the workpiece must be
designed in such a way that, standard broaches can be
used.
Broaching
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Properties of Broaching
5. There is almost no limitation in the shape of the
workpiece that can be broached.
But, there are some limitations, such as,
● For internal broaching there should be an existing
hole in the workpiece through which the broach will
be passed,
● The part should be strong enough to resist
broaching forces.
6. Rotational motion can be added to the longitudinal
motion of the broach to permit broaching of spiral
grooves, as in spiral splines or in gun-barrel rifling.
Broaching
Broach Design
On a broach, each tooth is higher
than the previous one by an
amount called step, which
determines the depth of cut.
The depth of cut varies from
0.15 mm to 0.025 mm.
Too-large cuts impose large stresses on the teeth and the
work; whereas too-small cuts result in rubbing rather than
cutting action.
The depth of cut is primarily dependent upon the strength
and ductility of the metal being cut.
The pitch of the teeth determines the amount of chip that can
be produced, the gullet provides a space for the chip.
Broaching
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Broach Design
On pull broaches, the pull end has a special shape to be
connected to the pulling head of the broaching machine
by using broach pullers.
● Roughing teeth remove most of the material,

● Semifinishing teeth provide surface smoothness,
● Finishing teeth produce exact size.
● On some round broaches burnishing teeth are
provided for finishing.
Broaching
Broach Materials
Because of the low cutting speeds employed, most
broaches are made of alloy or High-Speed Steel
(HSS), even for some mass-production work.
When they are used in continuous mass-production lines,
particularly in surface broaching, tungsten carbide teeth
may be used, permitting them to be used for long
periods of time without resharpening.
Alloy or HSS broaches are sharpened by grinding.
Broaching
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Types of Broaches - Internal Broaches
1. Internal Broaches
● Used for broaching of insides of holes.
● Most internal broaches are of solid construction.
● Quite often, however they are made of

shells mounted on an arbor.
When the broach, or a section of it, is subjected to

rapid wear, a single shell can be replaced and will be
much cheaper than an entire solid broach.
Broaching
Types of Broaches - Surface Broaches

2. Surface Broaches
● Used for broaching of external surfaces.
● Small surface broaches may be of solid
construction, but larger ones usually are
built up from sections which makes the broach
easier and cheaper to construct and sharpen.
It also often provides some degree of interchangeability
of the sections.
Broaching
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Surface Broaching
Broaching a gear segment
Broach with inserts
Broaching
Making Keyways by Broaching

Broach is continuously pulled through the
workpiece by the broaching machine.
By using broaches with different sizes, it is possible
to machine keyways with different sizes.
Broaching
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Pot Broaching
Broaching
Broaching Machines
Broaching machines are relatively simple.
Their primary functions are to impart plain reciprocating
motion to the broach and provide a means for
automatically handling the broach.
Broaching
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Broaching Machines
1. Vertical Broaching Machines
● Broaching presses (for push broaching)
● Pull-down broaching machines
● Pull-up broaching machines
● Surface broaching machines
2. Horizontal Broaching Machines

● Pull broaching machines
● Surface broaching machines
● Continuous surface broaching machines
● Rotary Broaching Machines
Broaching
Vertical Broaching Machines

1. Broaching Presses
● Press with a guided ram,
used with push broaches,
only for internal broaching.
● Slow but inexpensive;
flexible and can be used for
other types of operations
such as bending and staking.
Push broaching
Broaching
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2. Vertical Pull-Down
Broaching
Machines
The workpiece is placed
on spherical seated
worktable when the
broach elevator is
raised.
The pulling mechanism
is below the
worktable.
Pull-down broaching
Broaching
Vertical Pull-Down Broaching Machines

During the operation, the
elevator lowers the
broach through the hole
in the workpiece, the pull
end of broach is engaged
by the puller, and the
broach is pulled through
the part.
The workpiece is removed
from the table, and the
broach is raised upward
to be engaged by the
elevator mechanism.
Broaching
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3. Vertical Pull-Up
Broaching
Machines
The working cycle is the
reverse of the pull-
down machine.
The workpiece is placed
below the table of the
machine, then the
handling mechanism
raises the broach
until it engages the
puller head. Pull-up broaching
Broaching
Vertical Pull-Up Broaching Machines

As the broach is pulled upwards, the
workpiece rests against the underside of
the table, and it is held there until the
broach has been pulled through.
The workpiece then falls free.
There is no need to remove it from the table.
Pull-up machines may have up to eight rams.
Because the workpieces need only be placed
in the machines, and the broach handling
and work removal are automatic, they are
highly productive.
For certain types of work, automatic feeding
devices can be provided.
Broaching
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4. Vertical Surface
Broaching Machines
The broaches are
mounted on guided
slides.
They are simpler but
much heavier than pull
or push broaching
machines.
Because there is no need
for handling the
broach, the operating
cycle is very short.
Broaching
Horizontal Broaching Machines

Longer strokes and the use of longer broaches than cannot
conveniently be accommodated in vertical machines are
made possible by horizontal machines.
1. Horizontal Pull-Broaching
Machines
● Like vertical machines turned
on their sides.
● Generally used for large
holes.
● Broaching that requires
rotation of the broach, as
rifling and spiral splines,
usually is done on horizontal
machines.
Broaching
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2. Horizontal Surface
Broaching
Machines
As in the vertical
type, the broaches
are mounted on
heavy, ram-driven
slides.
Broaching

3. Continuous Surface
Broaching Machines
● Broaches are stationary, and the
workpiece is pulled past them on
an endless conveyor.
● Fixtures usually are attached to the
conveyor chain so that the
workpieces can be placed in them
at one end of the machine and
removed at the other, sometimes
automatically.
● There is no lost time due to
noncutting, reciprocating strokes.
● Such machines are being used
increasingly in mass-production
lines.
Broaching
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4. Rotary Broaching Machines
● Broaches are stationary, and the work is passed beneath
or between them, while held in fixtures on a rotary table.
● There is no lost time due to noncutting, reciprocating
strokes.
● Used in mass-production.
● Operating principle is similar to continuous surface
broaching machines.
● Looks like a rotary table milling machine;
where milling cutters are replaced by
broaches.
Broaching
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8 Broaching

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Broaching

Broaching is a unique machining process in which chips

● Roughing teeth remove most of the material,

● Quite often, however they are made of

When the broach, or a section of it, is subjected to

Types of Broaches - Surface Broaches

Broaching a gear segment

Broach with inserts

Making Keyways by Broaching

2. Horizontal Broaching Machines

Vertical Broaching Machines

Vertical Pull-Down Broaching Machines

Vertical Pull-Up Broaching Machines

Horizontal Broaching Machines

Horizontal Broaching Machines

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