1. COLLEGE :- SHREE SA’D VIDYA MANDAL INSTITUTE OF TECHNOLOGY
TOPIC :- BROCHING MACHINE
NAME OF THE STUDENT
RANA KEVAL PATEL DIPAL PATEL AFZAL
D D D11
NAME OF SUBJECT:-MANUFACTURING PROCESS-1 DEPARTMENT: MECHANICAL ENG.

2. INTRODUCTION:-
Broaching is a machining process that uses a toothed tool, called a broach, to remove material.
Broaching is an unusual machining process because it has a feed built into the tool.
A broach is effectively a collection of single point cutting tools arrayed in sequence , cutting one after the other, its cut is analogous to multiple passes of a shaper.

3. A broach is a special multipoint cutting tool.
Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool.
The broach contains three distinct sections:-
one for roughing,
another for semi-finishing
the last one for finishing.

4. THE BROACH:-
Broaching speed very form 20 to 120 surface feet per minute.
This result in a complete cycle time of 5 to second.
Most of the time is consumed by the return, stroke, broach handling, and work piece loading and unloading.

5. The broach is a special purpose tool with a series of regularly spaced teeth.
It may be made in one piece called solid broach or built up from replaceable section.
Internal broaches are usually of the solid type but surface broaches are built up with inserted teeth.
The portion of the broach from the puller end to the first tooth is known as the shank.
It is composed of the keyed or the pull end and the front pilot.
A broach is capable of removing material up to 6mm deep in one stroke.

6. Classification of broaching machine:-
According to direction of cutting:-
Horizontal Broaching machine
Vertical Broaching machine
Continuous Broaching machine
According to the purpose:-
Internal Broaching machine
External Broaching machine
According to the construction of the broach tool:-
Solid Broaching machine
Inserted Tooth Broaching machine
Progressive cut Broaching machine
Built-up Broaching machine

7. According to the function:-
Keyway Broaching machine
Burnishing Broaching machine
Round hole Broaching machine
Surface Broaching machine
According to the number:-
Single Broaching machine
Double Broaching machine
Multiple side Broaching machine
According to the motion:-
Straight line Broaching machine
Stationary Broaching machine

8. TYPES OF BROACHING:- Surface broaching:-
Internal Broaching
Surface broaching:-
Surface broaching is very simple as either the work piece is moved against a stationary ,surface broach or a work piece is held stationary while the broach is moved against it.

9. Surface Broaches:-
Slab Broach:- The slab Broach is the simplest surface broach. It is general purpose tool for cutting flat surfaces.
Slot Broaches are for cutting slots of various dimension at high production rates. Slot broaching is much quicker than milling when more than one slot needs to be machined, because multiple broaches can be run through the part at the same time on the same broaching machined.

10. Contour broaches are designed to cut concave, convex, cam-contoured ,and irregular shaped surface.
Pot broaches are cut the inverse of an internal broach, they cut the outside diameter of a cylindrical work piece.
Straddle broaches use to slab broaches to cut parallel surfaces on opposite sides of a work piece in one pass.

11. HORIZONTAL BROACHING MACHINE:-
In this type, the broach moves in horizontal direction relatively with the work piece. Otherwise, the work piece is set in horizontal motion relative to the broach.
Both internal and surface broaching can be performed using HBM.
Horizontal broaching machines use a slide with a horizontal motion.
They are generally of the pull type.

12. They have the disadvantage of occupying more space than vertical broaching machine.
They capacities range from 20 to 600 KN and strokes up to 3m.
Horizontal surface broaching machines are available with capacities of up to1000KN and strokes up to 9m.
The first broach is brought to the operating position and pulled through the work piece.
After the broach is returned to its original position the turret is indexed to bring the next broach into the operating position and so on.

13. VERTICAL BROACHING MACHINE:-

14. VERTICAL BROCHING MACHINE:-
The working of vertical broaching machine is similar to that of horizontal broaching machine.
Here, either the broach is set in vertical motion instead of horizontal machine.
It is further classifies into 3 type:
pull up type
pull down type
push down type

15. This type of machine essentially consists of a column, a base a table and the broach slide.
Majority of machines used in industry are of the vertical design.
The cycle can be made fully automatic and continues.
Vertical internal broaching machines may be of pull up ,pull down or push down type.
The pulling mechanism is in the base of the machine.
After the finished work piece has been removed, the tool rises and is returned to the starting position by the upper holder.

16. The chips are carried down with the broach and full through the hole.
The work holding fixtures, if used, can also be easily positioned and located in pull down broaching.
The broached parts can directly fall by gravity into a collecting chute from where they are carried out.
Both pull up and pull down type internal broaching machines are available in capacities from 20to 500KN.
Surface broaching machines are available in capacities from 30 to 300 KN and stroke of up to 2.5m.

17. CONTINUOUS BROACHING MACHINE:-

18. CONTINUOUS BROACHING MACHINE:-
This type is used for mass production of smaller parts.
The broaches are fitted into a belt driven by a set of pulleys, such that work piece is held normal to the broach.
Large quantities of small parts are often surface broached on continuous broaching machines.
In these machines work piece mounted in a series of work holding fixtures are continuously fed to a stationary broach and machined at a fast rate.

19. Two types of continuous broaching machines are in common use:-
Rotary continuous broaching machine
Chain type continuous broaching machine
After the fixtures pass the broach, the work piece are again automatically released by a cam and can be removed.
In both the machines the work piece are accurately guided through the broaching section.
When the broaching is complete the finished part is pulled on to the exit conveyor with a wire cable while the fixture returns to the starting position for reloading.

20. ROTARY BROACHING MACHINE:-
This machine has rotary table and vertical column. the broach is fitted horizontally above the table.
A series of fixture are mounted on the rotary table for locating and holding work piece. they move past the stationary broaches.
Rotary broaching machines are limited to small parts. They are used for squaring distributer shaft, slotting and facing smaller parts.

21. BROACHING OPERATIONS:-
INTERNAL BROACHING:-
Internal broaching is used for producing holes, key ways, spines, gear teeth, serration, and other contoured surfaces.
For many applications where a hole already exists and lot size is reasonable, broaching may be preferred to punching because of better dimensional accuracy.
The job to be internally broached must have a drilled or cored hole larger than the size of the pilot of the broach.

22. Rotary – cut Broaching:-
Rotary cut broaching is a special type of internal broaching used with cored or punched holes.
When round broaches are used with such holes the first tooth encounters a hard scale layer which might cause a rapid wear.
When the first tooth is worn out the second tooth has not only to take its designed cut but must also remove the material left uncut by the worn out first tooth.
The might lead to damaging of these teeth and hence a need for broach resharpening.

23. Double cut Broaching:-
This is another type of internal broach designed for heavy stock removal and getting below the scale.
This type of broaching is used for flat surfaces, round holes and other shapes.
The power required for double cut broaching is lower than that required for the rotary cut broaching but the broaches are longer than the conventional broaches.

24. External Broaching:-
External or surface broaching is used for machining flat surfaces such as automobile cylinder heads and gear teeth.
It is usually done on surface broaching machine.
Sometimes simple surface broaching operation can also be done on internal broaching machines with suitable fixture.
The external broaching tools are mounted on a slider which is given a guided motion over the length of the job.

25. Progressive Broaching:-
Each cutting tooth takes a cut of pull depth but covers only a small width.
As the broach passes over the surface of the work piece different teeth take their respective cut so that in one pass the entire width of the work piece is covered.
A set of full width teeth located behind the apex of the v helps In finishing the surfaces.

26. Straddle Broaching:-
A broaching operation requiring two or more parallel opposed surfaces to be machined may be done faster by machining all such surface together with suitably mounted broaches.
Such a broaching is known as straddle broaching.
The work piece is clamped in a fixture for properly locating the surfaces to be broached.

27. ADVANTAGES:-
High accuracy and a high class of surface finish is possible.
Both roughing and finishing cuts are completed in one pass of the tool.
The process can be used for a either internal or external surface finishing.
Any form that can be reproduced on a broaching can be machined.

28. LIMITATIONS:-
High tool cost. A broach usually does only one job and is expensive to make and sharpen.
Very large work piece cannot be broached.
The surfaces to be broached cannot have an obstruction.
Broaching cannot be used for the removal of a large amount of stock.

29. THANK YOU