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Broaching is a process in which a cutting tool passes over or through a part piece to produce a desired form. A broach removes part material with a series of teeth, each one removing a specified amount of stock.
There are a number of companies working to change the way broaching is perceived, and over the past 10 years, they’ve incorporated significant technological changes to make the process more flexible, productive and accurate.
Faster, more efficient manufacturing offered with table-top design from American Broach & Machine.
In 1964, a young and tidy Bob Dylan sang away in that infamous voice of his, all nasally and grating yet wonderfully distinct, opining to the fervent masses: “The times, they are a-changin.”
The cutting tool is basic to gear manufacturing. Whether it's a hob, broach, shaper cutter or EDM wire, not much gets done without it. And the mission of the tool remains the same as always; removing material as quickly, accurately and cost-effectively as possible. Progress in the field tends to be evolutionary, coming gradually over time, but recently, a confluence of emerging technologies and new customer demands has caused significant changes in the machines, the materials and the coatings that make cutting tools.
In this discussion of gear roll-finishing particular attention is called to the special tooth nomenclature resulting from the interaction between the rolling die teeth and the gear teeth. To eliminate confusion the side of a gear tooth that is in contact with the "approach" side of a rolling die tooth is also considered to be the approach side. The same holds true for the "trail" side. Thus, the side of the gear tooth that is in contact with the trail side of a rolling die is also considered to be the trail side.
The forming of gear teeth has traditionally been a time-consuming heavy stock removal operation in which close tooth size, shape, runout and spacing accuracy are required. This is true whether the teeth are finished by a second forming operation or a shaving operation.
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Rotary gear honing is a hard gear finishing process that was developed to improve the sound characteristics of hardened gears by: Removing nicks and burrs; improving surface finish; and making minor corrections in tooth irregularities caused by heat-treat distortion.
Users of gear-cutting tools probably do not often consciously consider the raw material from which those hobs, broaches or shavers are made. However, a rudimentary awareness of the various grades and their properties may allow tool users to improve the performance or life of their tools, or to address tool failures. The high-speed steel from which the tool is made certainly is not the only factor affecting tool performance, but as the raw material, the steel may be the first place to start.
Quality gear manufacturing depends on controlled tolerances and geometry. As a result, ferritic nitrocarburizing has become the heat treat process of choice for many gear manufacturers. The primary reasons for this are: 1. The process is performed at low temperatures, i.e. less than critical. 2. the quench methods increase fatigue strength by up to 125% without distorting. Ferritic nitrocarburizing is used in place of carburizing with conventional and induction hardening. 3. It establishes gradient base hardnesses, i.e. eliminates eggshell on TiN, TiAIN, CrC, etc. In addition, the process can also be applied to hobs, broaches, drills, and other cutting tools.
Hobs, broaches, shaper cutters, shaver cutters, milling cutters, and bevel cutters used in the manufacture of gears are commonly made of high speed steel. These specialized gear cutting tools often require properties, such as toughness or manufacturability, that are difficult to achieve with carbide, despite the developments in carbide cutting tools for end mills, milling cutters, and tool inserts.
It has long been known that the skiving process for machining internal gears is multiple times faster than shaping, and more flexible than broaching, due to skiving's continuous chip removal capability. However, skiving has always presented a challenge to machines and tools. With the relatively low dynamic stiffness in the gear trains of mechanical machines, as well as the fast wear of uncoated cutters, skiving of cylindrical gears never achieved acceptance in shaping or hobbing, until recently.
The capabilities and limitations of manufacturing gears by conventional means are well-known and thoroughly documented. In the search to enhance or otherwise improve the gear-making process, manufacturing methods have extended beyond chip-cutting - hobbing, broaching, shaping, shaving, grinding, etc. and their inherent limitations based on cutting selection and speed, feed rates, chip thickness per tooth, cutting pressure, cutter deflection, chatter, surface finish, material hardness, machine rigidity, tooling, setup and other items.
"Holding Gears in Place for Quick Operations" and "Machine Broaches Unusual Sized Gears."
News Items About broach
1 duMonts Keyway Broach Sets Cuts Complete Range (February 21, 2007)
A heavy duty set of keyway broaches, bushings and shims designed for cutting a complete range of keyways from 1/8" to 3/4" without duplic... Read News
2 Polygon Solutions Designs Rotary Broaching Brake (October 5, 2012)
Rotary broaching can be utilized for making small forms like hexagons and squares in soft materials like aluminum, brass and mild steel. ... Read News
3 Polygon Offers Rotary Broach Drill (November 12, 2012)
Polygon Solution’s Rotary Broach Form Drill is a new tool used to improve manufacturing processes used in rotary broaching. Rotary ... Read News
4 Slater Tools Introduces Rotary Broaching Tool Holder (February 14, 2007)
Slater Tools Inc. released a new, adjustment-free rotary broaching tool holder designed for Swiss- type machines. Slater's new adj... Read News
5 BCI Purchases Broaching Machine (February 11, 2010)
Bremen Castings broached its first casting in January from its in-house machine shop in Bremen, Indiana. The Colonial Horizontal 1... Read News
6 The Broachman Joins American Broach & Machine (April 20, 2006)
Ken Nemec, a.k.a. "The Broachman", was hired by American Broach & Machine as marketing manager. According to the company's press r... Read News
7 Executive Promotions at Ohio Broach (January 19, 2006)
Charles P. Van De Motter was promoted to CEO and chairman of the board at Ohio Broach & Machine. Van de Motter previously worked as p... Read News
8 New Representation Agreement for Ohio Broach (January 1, 2004)
The Ohio Broach & Machine Co. has appointed New England Industrial Sales Associates as its sales representatives for Connecticut, Vermont... Read News
9 Broaching Machine Specialties Completes ISO Registration (March 2, 2005)
Broaching Machine Specialties of Novi, MI, was awared a certificate of registration for ISO 9001:2000 conformance for the design, manufac... Read News
10 American Broach to Establish R&D Center (February 15, 2011)
American Broach & Machine Company will establish a new research and development center in the Ann Arbor region. Today, the ... Read News
11 Polygon Improves Process for Medical Implant Broaching (July 2, 2013)
Innovation in orthopedic medical implants continues to improve. As a result, manufacturing processes required to make those parts are ada... Read News
12 Broaching Machine Specialties to Supply Ekin Products in North America (July 10, 2015)
Broaching Machine Specialties (BMS) recently announced a strategic partnership with Ekin of Bilbao, Spain.Ekin has been supplying machine... Read News
13 Polygon Solutions Offers Letter Broach (October 23, 2012)
Polygon Solution’s Letter Broach is a new cutting tool used to create letters or numbers in metal parts. The Letter Broach is used ... Read News
14 Mitsubishi Acquires Federal Broach (April 26, 2012)
Mitsubishi Heavy Industries, Ltd. (MHI) has signed an agreement with Federal Broach Holdings, LLC and its shareholders to acquire all of ... Read News
15 Federal Broach Announces New Coating Facility and Capabilities (March 9, 2016)
Federal Broach has completed installation of a new state-of-the-art coating facility. Federal Broach supplies full gear cutting tool serv... Read News
16 American Broach President Dies (May 24, 2007)
Ed Kokmeyer, former president of American Broach & Machine Co., died. Funeral arrangements are being handled by: Nie Funeral Ho... Read News