Learn about the broaching process

Learn about the broaching process

There is very little knowledge about broaching, broaching process, broaching machines, helical broaching, and broaching applications in engineering textbooks. Even if you ask well-trained engineers about what is broaching, they might not be able to answer with a clear idea. This series will introduce broaching and its applications that everybody can understand easily regardless of an engineering background.

What is broaching?

Broaching is a fast and precise cutting process

What is the use of broaching?

Broaching can be used to make round holes, splines, keyways, six-bolt grooves, square holes, special-shaped holes, and helical teeth. A high-level of customization is possible in the use of broaching according to various requirements.

What is broaching process?

Broaching process is that the broaching machine cut the part with the broach tool

For example, when processing internal splines, it is necessary to process the entire surface of the complex shape at one time; when processing helical teeth, the tool needs to rotate synchronously during broaching, and when processing the round hole in the aluminum product, multiple processes such as roughing, finishing, and burnishing can be integrated into one process.

How does the broaching process work?

When the broaching machine pushes or pulls through the workpiece’s surface, a hole is left on the workpiece, so for this series of actions, we call it the  broaching process.

Take the servo table-up broaching machine as an example. The broach first passes through the workpiece’s inner hole to be fixed in the puller below the working table, and then the working table rises for broaching. As the working table rises until it exceeds the tool’s last tooth, a workpiece is completed.

What is broaching advantages?

Fast machining speed

Depending on the workpiece’s shape and the amount of cutting, a small workpiece can be completed in about 6-30 seconds, and a medium or large workpiece can be completed in 30-90 seconds. The simultaneous processing of the fentire surface makes the broaching machine much faster than other cutting processes when the shape is complicated. It is especially suitable for mass production.

Stability in size

The machines and tools used in broaching are designed for mass production. No matter how complex the shape is, the quality data obtained under mass processing is quite stable. The operator’s technical requirement is not high, which can further reduce the quality fluctuation caused by human factors.

Overcome difficulties in shapes and quantity

Long-hole keyways, splines, and slots that are difficult to machine on lathes are much easier to process on internal broaching machines; the time-consuming process of making external teeth on milling machines can be completed in seconds on external broaching machines.

When you encounter limitations in shapes or quantity, try putting broaching into consideration.

No need for programming

When replacing different workpieces, if the size is close, replace the tool; if the size difference is massive, to replace jigs, broaches, and pullers is also very simple.

In the hydraulic broaching machine, the broaching stroke is controlled by the position of the sensors, and the functions used are also quite simple; in the servo broaching machine, whether it is collecting processing information or setting the stroke, it can be visualized Direct operation in the man-machine interface, no programming at all.

Automation is available

The broaching machine can run all day with automation. There are additional I/O to connect with other pieces of equipment in the customer’s factory, which significantly reduces labor costs, minimizes instability, and continuously optimizes the production performance.