Podcast
Questions and Answers
What is the primary use of external broaching?
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?
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?
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?
What surface roughness values can be achieved when broaching mild steels?
What effect do rake face chamfers have on broaches?
What effect do rake face chamfers have on broaches?
In what scenarios can acceptable broaching results be expected when using case hardening steels?
In what scenarios can acceptable broaching results be expected when using case hardening steels?
What is the purpose of reserve teeth in internal broaching?
What is the purpose of reserve teeth in internal broaching?
What type of broaching is used for machining external teeth and guiding surfaces?
What type of broaching is used for machining external teeth and guiding surfaces?
What is the primary function of broaching as a metal cutting technique?
What is the primary function of broaching as a metal cutting technique?
Which of the following best describes internal broaching?
Which of the following best describes internal broaching?
What is one advantage of broaching over reaming for generating holes?
What is one advantage of broaching over reaming for generating holes?
What types of shapes can internal broaching produce?
What types of shapes can internal broaching produce?
In external broaching, what type of contours are typically finished?
In external broaching, what type of contours are typically finished?
Which of the following statements about broaching is false?
Which of the following statements about broaching is false?
What is a common application of internal broaching?
What is a common application of internal broaching?
Which component of the broaching tool is responsible for the cutting action?
Which component of the broaching tool is responsible for the cutting action?
Flashcards
Broaching
Broaching
A metal cutting technique using a multi-edged tool, where the tool itself performs the cutting motion. Material is removed in a single stroke (pulling or pushing) with the broach.
Internal Broaching
Internal Broaching
A type of broaching where the tool is fed into a pre-machined hole in the workpiece. The broach, with multiple cutting teeth, is then pulled or pushed through, creating the desired shape inside the workpiece.
External Broaching
External Broaching
A type of broaching where the tool finishes the pre-machined external contour of a workpiece, like the opening of a wrench.
What are some applications of Internal Broaching?
What are some applications of Internal Broaching?
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Why is Broaching often used instead of reaming?
Why is Broaching often used instead of reaming?
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How does the broaching method achieve high accuracy?
How does the broaching method achieve high accuracy?
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What is the economic benefit of broaching?
What is the economic benefit of broaching?
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Christmas Tree Grooves
Christmas Tree Grooves
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Broaching Accuracy
Broaching Accuracy
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Surface Quality in Broaching
Surface Quality in Broaching
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Surface Roughness (Rt)
Surface Roughness (Rt)
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Broaching Tools
Broaching Tools
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Broach Components
Broach Components
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Rake Angle and Clearance
Rake Angle and Clearance
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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.
