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Broaching, Sawing andFiling
Chapter 27
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Broach
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Broaching Process Originally developed for producing
internal keyways. Multi-tooth cutter, single pass operation sed in production to !nish holes,
splines, and "at surfaces. #apid operation, low cycle ti$es. %& 2' to (' ft)$in* +cellent surface !nish produced %2 to
2( $icro-inches* +cellent tolerance
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Broach Construction /ong $ultitooth cutter with
progressively deeper teeth, rise
per tooth #ise per tooth0
1urface0 '.'' to '.'' inches)tooth
3nternal0 '.'' to '.''2( inches)tooth Chips produced are held in tooth
gullet during process
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Broach Construction Materials0
4igh 1peed 1teel 411 with 5i6 coating 5ungsten Caride teeth %$ass prod.*
1tyles0 1olid 1hell 1ections %larger surface*
1hapes
4oles %round, s8uare, he, 9* :eyways 3nternal 1plines and gears ;lat surfaces 1piral splines, gun arrel ri"ing
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Broaching #e8uire$ents5wo teeth contact surface
Part $ust e ale to withstand
high forces %( to '' tons)in2*
1urface $ust e accessile
4igh tool cost
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Broaching Machines Presses
&ertical Pull
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Broaching Machines&ertical -
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Broaching Machines&ertical 1urface
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Broaching Machines
4ori>ontal
Capacity0 -2' tons Cutting 1peed0 (-?'
;PM
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Broaching Machines 4ori>ontal
1urface Broach
' ton 2'= screw drive
Operation0 roach@et engine turine
wheel rotor slots
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Broaching Machines Continuous Chain Broach
Part0
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1awing Three styles of blades
4acksaw
Bandsaw
Circular or cold saw
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1awing Blade Material
4acksaw, 411
Bandsaw %teeth electron ea$ welded tosteel ack* 411 teeth 411 with 5i6 coating
5ungsten Caride 5ungsten Caride grit
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1aw 5ooth ;or$ #egular, 1tandard,
Precision
1kip, Buttress
Claw, hook
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1aw 5ooth 1et #egular
lu$inu$,plastics wood
#aker eneral Purpose
Cutting
Dave Cutting thin $aterial
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Blade Construction
Didth e of teeth ullet si>e 6u$er of teeth in contact with work
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Machinery&ertical Bandsaws
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Machinery4ori>ontal Bandsaws
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Machinery
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Machinery/arge
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Machinery
Cold 1aw 411, Caride 5ipped Blades
Manual uto$atic
?= to E= lade
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Machinery
Power 4acksaw ccelerated
return stroke ofsaw ow
Cuttingcapacities up toE=
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;iling
sed to re$ove s$all a$ounts of$aterial
1hapes
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;iles
$erican Pattern
6eedle ;iles
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5ypes of 5eeth
1ingle Cut #ows of teeth at (H-E(H
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;ile Coarseness
$erican Pattern ;iles 1$ooth
1econd Cut Bastard
1wiss Pattern ;iles
6o. '', ', , 2, , ? and 5he degree of coarseness is
greater for longer !les
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;iling Machines
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;iling Machines
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;iling Machines
Band ;ilingMachine
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#otary Burrs