Broaching Machines & Helical broaching: Learn about the broaching process

What is broaching?

What is broaching process

There is very little knowledge about broaching and its 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 machine?

Broaching is a fast and precise cutting process

Broaching can be used to make round holes, splines, keyways, six-bolt grooves, square holes, hexagonal holes, special-shaped holes, helical teeth, etc., quickly and precisely. High-level of customization is possible according to various requirements.
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.

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

The broaching needs to be performed by a broaching machine with a broach.

What is a broach? A broach is a tool with many circular blades arranged from small to large. Standard broaches include a shank part for clamping and guiding, a blade part including roughing teeth and finishing teeth, And the lifting part used to lift the tool. The structure is shown in the figure below.

Takes 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.

The advantages of broaching

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 entire 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.

What are the types of broaching machines in Axisco?

There are four types of broaching machines in Axisco. CNC helical broaching machines, servo table-up broaching machines, hydraulic internal broaching machines, hydraulic surface broaching machines. We integrate tools, fixtures, and the machine in all kinds of broaching machines as a turn-key solution.If you want to make multiple slots or complex shapes at your product’s surface in large quantities, the surface broaching machine is an excellent choice for you. During broaching, the workpiece clamped on the working table, the broach tool cut from the other side to finish the broaching.

What is helical broaching?

CNC helical broaching machines

It is a machine that can process helical teeth precisely with a CNC system. It is highly intuitive and convenient to set the helical direction, pitch circle diameter, and lead angle in the human-machine interface.

During processing, the tool rotates, and the working table drives the workpiece to move upward synchronously to complete broaching.

Learn more: Why do people choose CNC Broaching Servo Broaching Machines?

Servo table-up broaching machines

In a servo table-up broaching machine, the tool does not move during cutting, and the working table drives the workpiece to move upward to complete the broaching. This equipment uses electricity as the primary source of power. Compared with a hydraulic broaching machine, a servo broaching machine has better energy efficiency and is more friendly to the environment.

All parameters, such as the broaching speed, return speed, stroke, etc., can be controlled through the human-machine interface. The operator only needs to stand on the ground to operate, without digging a pit or standing on stairs.

Hydraulic internal broaching machines

A classic choice of broaching machines. Most of the broaching machines in the world are hydraulic broaching machines.

Compared with the servo broaching machine, Axisco’s hydraulic internal broaching machine is more economical in price, with the same excellent accuracy performance, and can be made into huge tonnages (over 100 tons) according to customer needs.
During broaching, the working table does not move, and the tool moves downwards. Therefore, the height of the working table is relatively high. When operating, customers might need to dig pits or stand on stairs.

Hydraulic surface broaching machine

If you want to make multiple slots, or complex shape at the surface of your product in large quantity, the surface broaching machines are very good choice for you. The workpiece clamped on the working table, the broach tool cut from the other side to finish the broaching.

Learn more: How surface broaching works? The benefits of surface broaching.

The way of using different types of broaching machines

Left：A hydraulic broaching machine putting in a pit

Middle: A hydraulic broaching machine with stairs

Right: A servo table-up broaching machine that the operators can stand on the ground

Why shall I come to Axisco for broaching requirements?

Axisco is recognized by customers in more than 30 countries worldwide and has more than 35 years of experience. Our customers are all over the aerospace, automobile, gear, bicycle, hand tools, locks, hydraulic valve parts, electronic parts, and various hardware industries. We have a complete broaching solution, including CNC helical broaching machines, servo broaching machines, hydraulic internal broaching machines, and hydraulic external broaching machines. Machines are in different tonnages and different strokes according to customer needs. The professional team can quickly respond to various customized mechanisms, fixtures, tools, and automation integration needs.

 

More About Broaching

Surface Broaching

Surface broaching, also known as external broaching, refers to cutting single grooves, multiple grooves, or special shapes on an object’s surface or edge.
More about surface broaching: How surface broaching works? The benefits of surface broaching

CNC Broaching and Servo Broaching

Servo broaching machine uses electricity as the primary source of power. The servo drive can accurately control a large broaching force with a tiny signal.
More about CNC broaching: Why should choose CNC Broaching and CNC Servo?

Spline Broaching

When we want to transfer rotary motion from one point to another in any device, we commonly rely on a spline connection.
More about Spline broaching: Spline broaching: Learn our service & spline broach machine

Pull Broach Machines

Pull broaching is a technology to cut complicated shapes in one pass. The collaboration of the machine, the tooling, & the fixture is crucial for making high precision products.
More about Pull broach machine: Hydraulic Internal Pull Broach Machine 10 ton 1500 mm

Broach Cutting Tools & Spline Broaching Tools

Broach refers to the tool for the majority of heavy-duty tools and fine sharpener, which is mainly installed in broaching machine.
More about Broach Cutting Tools:Broach cutting tool & Spline broaching tool

How to inspect broaching machines remotely?

When having machine inspections, it is challenging to let buyers feel confident about machine quality when they can not see and touch the machine themselves. Luckily, with the application of the internet and technology, those are no longer problems.
More about broaching machine inspections: How did Axisco help customers inspect broaching machines remotely during the pandemic?