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Back around 2005-2010, the most exciting things that were happening in broaching had little to do with broaching. What was happening - and continues to evolve today - was the emergence of on-the-edge CNC, software and servo drive technology. Together, they practically transformed a metalworking process as old as water into a viable, alternative consideration for producing high-volume part runs.
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.
Broaching is a machining technique commonly used to cut gear teeth or cam profiles for the high volume manufacture of power transmission parts used in vehicles (Refs. 1–2). This article shows how the right gear blank material can make all the difference if you want to get more parts out of each tool.
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.”
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.
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.
During a year with a strong dollar, tanked oil prices and a number of soft markets that just aren't buying, one might expect spline manufacturers to be experiencing the same tumult everyone else is. But when I got a chance to speak with some of the suppliers to spline manufacturers at IMTS about how business is going, many of the manufacturing industry's recent woes never came up, and instead were replaced by a shrug and an "eh, business is doing pretty well."
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.
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.
News Items About broaching
1 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
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 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
4 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
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 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