Definition of broaching operation | it's, types application application

Broaching operation:

• Broaching operation is a machining process that involves the use of a multi-point cutting tool called a broach to produce a desired shape or form on a workpiece. The broach is a long, narrow tool with a series of cutting teeth along its length, arranged in a precise sequence that corresponds to the desired shape or form of the workpiece.
• During a broaching operation, the workpiece is typically held stationary while the broach is inserted into it and pulled through, cutting the desired shape or form in a single pass. The cutting teeth on the broach remove material from the workpiece as it is pulled through, creating a finished surface that matches the shape of the broach.
• Broaching can be used to produce a wide variety of shapes and forms, including keyways, splines, gears, and other internal or external profiles. It is commonly used in the production of precision parts for the automotive, aerospace, and manufacturing industries.

Broaching operation process:

Here are the steps involved in a typical broaching operation process:

1. Set up the workpiece: The workpiece is clamped securely in a vise or fixture to ensure that it does not move during the broaching operation.

2. Choose the appropriate broach: The broach is selected based on the shape and size of the desired cut. The broach consists of a series of teeth that gradually increase in size to create the desired shape.

3. Set up the broaching machine: The broaching machine is set up to match the size and shape of the broach. This involves adjusting the feed rate, cutting speed, and other parameters.

4. Perform the broaching operation: The broach is inserted into the workpiece and slowly pushed or pulled through the material. As the broach moves through the material, it removes chips of metal, gradually creating the desired shape.

5. Inspect the finished part: Once the broaching operation is complete, the finished part is inspected to ensure that it meets the required specifications. Any necessary finishing operations, such as deburring or polishing, may also be performed at this stage.

Overall, broaching is a precise and efficient metalworking process that is widely used in manufacturing to create complex shapes and contours in a variety of materials.

Classification of Broaching operation:

Here are some common classifications of broaching:

1. Based on the type of broach:

• Surface broaching: This type of broaching is used to produce flat surfaces on a workpiece. The broach has teeth along the length of the tool, and each tooth removes a small amount of material from the workpiece.

• Internal broaching: This type of broaching is used to create internal features such as keyways, splines, and gears. The broach has teeth that match the shape of the desired feature, and each tooth removes material as it is pushed through the workpiece.

• External broaching: This type of broaching is used to create external features such as hexagons, squares, and other polygonal shapes. The broach has teeth that match the shape of the desired feature, and each tooth removes material as it is pulled through the workpiece.

2. Based on the direction of the broach:

• Vertical broaching: In this type of broaching, the broach is moved vertically through the workpiece.

• Horizontal broaching: In this type of broaching, the broach is moved horizontally through the workpiece.

3. Based on the method of operation:

• Push broaching: In this method, the broach is pushed through the workpiece using a hydraulic or mechanical press.

• Pull broaching: In this method, the workpiece is pulled over the broach using a broach puller.

• Surface broaching: In this method, the workpiece is held stationary while the broach is moved across its surface.

Application of Broaching 

Broaching is commonly used in manufacturing for a variety of applications, including:

• Keyway cutting: Broaching is often used to create keyways in gears, pulleys, and other components where a key is needed to transmit Torque

• Splining: Broaching can be used to create splines on shafts, which are ridges or teeth that help transmit torque

• Hole shaping: Broaching can be used to create non-round holes such as hexagons, squares, and other shapes.

• Surface finishing: Broaching can be used to create a smooth surface finish on a workpiece.

• Gear cutting: Broaching can be used to create internal and external gears with high precision.

• Medical implants: Broaching is used in the manufacturing of medical implants, such as hip and knee replacements, to create precise shapes and forms.

• Aerospace components: Broaching is used in the manufacturing of aerospace components such as turbine blades, compressor discs, and landing gear components.

Overall, broaching is a versatile machining process that can be used for a wide range of applications where precision and accuracy are required.

Advantage and disadvantage of Broaching operation:

Advantages of broaching:

Precision: Broaching can produce highly precise shapes and finishes, making it ideal for producing complex parts with tight tolerances.

Efficiency: Broaching is a fast machining process that can produce a finished part in a single pass, reducing the need for multiple machining operations and increasing productivity.

Versatility: Broaching can be used to produce a wide range of shapes and sizes, including internal and external shapes, splines, keyways, and gears.

Cost-effectiveness: While broaches can be expensive, they are often more cost-effective than other machining processes when producing large quantities of parts.

Disadvantages of broaching:

Initial cost: Broaches can be expensive to produce, which can make the initial setup costs for broaching higher than other machining processes.

Limited flexibility: Broaching is a specialized process that requires specific tools and machinery, making it less flexible than other machining processes.

Material limitations: Broaching is best suited for machining softer materials such as aluminum, brass, and plastics. It can be more difficult and time-consuming to broach harder materials like steel.

Surface damage: Broaching can produce a lot of heat and friction, which can cause surface damage to the workpiece. This can be mitigated by using lubricants and coolants, but it is still a potential disadvantage of the process.