Broaching Techniques and Applications

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Questions and Answers

What is the primary use of external broaching?

To apply surface coatings

To manufacture shaped grooves (correct)

To generate internal profiles

To drill holes in materials

What is the range of accuracy values typically achieved with broaching?

IT 7 to IT 8 (correct)

IT 9 to IT 10

IT 4 to IT 5

IT 6 to IT 8

Which factor significantly affects the surface quality during broaching?

Speed of the broaching machine

Thickness of the workpiece

Depth of the final finishing cut (correct)

Type of lubrication used

What surface roughness values can be achieved when broaching mild steels?

Rt = 6.3 to 25 µm Signup and view all the answers

What effect do rake face chamfers have on broaches?

They reinforce the wedge and slightly reduce positive properties Signup and view all the answers

In what scenarios can acceptable broaching results be expected when using case hardening steels?

If it has a homogeneous ferrite-perlite distribution Signup and view all the answers

What is the purpose of reserve teeth in internal broaching?

To improve surface quality by regrooving and shaving Signup and view all the answers

What type of broaching is used for machining external teeth and guiding surfaces?

External broaching Signup and view all the answers

What is the primary function of broaching as a metal cutting technique?

To cut material in one motion without the need for feed motion Signup and view all the answers

Which of the following best describes internal broaching?

Producing a contour by moving the tool through an opening Signup and view all the answers

What is one advantage of broaching over reaming for generating holes?

Broaching is faster and produces complex geometries in one stroke Signup and view all the answers

What types of shapes can internal broaching produce?

Shapes such as serrations, taper bushings, and spline profiles Signup and view all the answers

In external broaching, what type of contours are typically finished?

Outer contours like those on tools such as wrenches Signup and view all the answers

Which of the following statements about broaching is false?

Broaching requires multiple passes to achieve desired dimensions. Signup and view all the answers

What is a common application of internal broaching?

Forming precise shapes like spline profiles for gears Signup and view all the answers

Which component of the broaching tool is responsible for the cutting action?

The broach's cutting teeth Signup and view all the answers

Study Notes

Broaching Definition

Broaching is a metal cutting technique using a multi-edged tool.
The tool performs the cutting motion without feed motion.
Material removal occurs in one stroke (pulling or pushing).
The tool is called a broach.

Broaching Methods

Two types: internal and external broaching.

Internal Broaching

The broaching tool is inserted into a pre-machined opening.
The broach (with multiple cutting blades) is pulled or pushed through.
A specific contour (e.g., square, hexagon) is generated in the workpiece opening.

External Broaching

The broaching tool finishes a pre-machined outer workpiece contour.
An example is the opening of a forged open-end wrench.

Broaching Applications

Internal Broaching

Used to create openings of various shapes.
Examples include serrations, taper bushings, and spline profiles.
Broaching is used where high accuracy and shape are needed along with high surface quality.
Sometimes used instead of reaming to generate holes.
It's an economical method to generate complex geometries in one stroke.

External Broaching

Used to generate external profiles, including shaped grooves and guiding surfaces.
Examples include turbine blades, external teeth, and guide surfaces.

Achievable Accuracy/Surface Quality in Broaching

Achievable accuracy values range from IT 7 to IT 8.
Higher accuracy (IT 6) is possible with more effort.
Surface quality improves with final finishing teeth and additional reserve teeth.
Surface roughness values (R₁) for mild steel broaching range from 6.3 to 25 μm.
High surface quality is possible with free-cutting steels, case-hardened/tempered materials.

Broaching Tools

Broaching tools are composed of a shank, shank neck, inserting cone, insert, teeth, and support elements.

Broach Blade Geometry

Broach blades have rake angles and orthogonal clearances similar to turning tools.
Rake face chamfers are often omitted due to grinding complexities.
Land angles generally range between 0° and 0.5°.
Effective blade geometry leads to efficient cutting and increased accuracy.

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Description

Explore the metal cutting technique known as broaching. This quiz covers the methods, applications, and specific types of broaching, including internal and external processes. Assess your understanding of the tools and their roles in shaping materials with high precision.