Use Recommendations for Broaching Operations

Rotating Broach Rotary Broaching can be performed on turned parts as well as CNC machining centers or transfer-
machine. The only difference being that the broach holder is rotated in the machine spindle and the part is stationary
instead of the reverse condition on a lathe. Orientation of a profile and part can be accomplished with a drive on the
spindle nose which maintains the exact angular position required. In order to produce parts successfully there are some
basic rules that must be followed.

Cutting Principle - The tool is held at a 1 angle relative to the part centerline and has a 1 30 clearance angle built in.
The face of the broach tool is the pivot of the 1 angle and is
placed on centerline with the part. As the tool comes in 1

contact with the part, friction drives the broach to rotate

synchronously. The cutting edge is kept on center and the rest
of the tool oscillates around the part centerline with a wobble
effect. With the faces of the tool and part at a relative 1 angle,
only the leading point of the tool is cutting and not the entire
profile. The wobble effect moves the leading edge to rotate in 1xH H=hex size
and out of the cut like a cam. It shears the shape into the part 1.4 x H
with a scalloping effect as it advances forward. This reduces
the required thrust force up to 80% when it is at the optimum feed.

Coolant - Usual coolant or cutting oil

Broach Preparation - A 60 or 90 chamfer, slightly bigger than the largest dimension of the broach, is essential for and
easy start of the broach. When exact concentricity is required, counter bore the hole at the same size as the measured
profile across corners, boring approximately .020 deep will provide the best results.

Drilling The Hole - For internal broaching, the hole should be drilled approx. 1 % bigger than the diameter across the
flats of a hex shape. This percentage can be reduced in free cutting material and increased as machinability decreases.
In mild steel we recommend the following tolerances:

.059-.118 = .001- .002 .118-.236 = .0015-.0035 .236-.394 = .0025-.005 .394-.630 = .004-.008 > .630 = .006-.012

Drill Radius Not Allowed - When a drill radius is not allowed along the broached walls of the part, tool life and bearing
life will be reduced. When exact concentricity is required, cbore, drill and pre-bore the hole which will keep the broach
concentric when it enters the hole. With such a tight fit push back may result as the broach becomes a hydraulic ram.
This pressure can be relieved with a vent hole supplied in the broach tool.

Drilling Depth - Drill the hole as deep as possible to leave room for chip accumulation. We recommend a depth of 1.3 to
1.5 times the length of the profile depth. Failure to drill to an adequate depth will cause premature tool life and will
damage the broach head.

Centering The Broach - Nothing is more important than having the cutter centered as close as possible to the center of
the work piece. Improper center setting will cause an uneven hole configuration, oversize holes and spiraling. The
maximum eccentricity should not exceed .0008 To simplify setup on more accurate Swiss Type and Gang Machines, use
our (on-center) 2100 Series holders. For easier setting on conventional CNC and other machines, use our gages 6189 or
6199 with the adjustable type broaching heads.

Broaching Rotation Speed - The basic principle of the 1 offset allows high speed application from 1500 up to 3000 rpm.
Rotational speed has very little effect on cutting action or tool life. The cutting edges of the broach tend to dig in to the
face of the part as the tool comes in to contact with the rotating material. When there is full contact they are in
synchronous rotation. At higher speeds this dig mark will become more pronounced and tool life will suffer. For Best
results start the broach operation at a slow rotation and then increase the speed when it is in full contact. Reversing the
spindle rotation half way into the part can reduce spiraling.

Feed Rate - The feed choice mainly depends on the material characteristics. In a mild-steel, we recommend .0012 -.0024
per revolution. If the machine thrust force is sufficient, the feed can be doubled even tripled as machinability increases. In
most cases the maximum feed rate should not exceed .03 x the profile diameter. A slower feed rate will produce an
improved finish with finer lines along the sidewalls of the broached hole. By increasing the feed rate the cutting cycle will
be faster but the broaching lines will be more pronounced leaving a coarse finish.

Broach Sharpening An external or internal broach tool can usually be sharpened one or two times if the tools are in
reasonable condition. Only the front face will be re-sharpened with a cutting angle from 4 to 8.
G:\Genevieve\Marketing & Products\Broaching\Use recommendations for broaching operations.doc
 Broach Setup
Series 2100
The 2100 Series holders, 2100 line, 2150 line, and 2160 line do not require centering with an indicator. These heads are
designed for machines with more accurate centering built into the machine. This would include Swiss Type, Gang type,
and small precision lathes, all of which are designed for small diameter precision turning. It is not generally recommended
to use the 2100 series broach head on conventional CNC turret type lathes due to the centering inaccuracy associated
with these lathes. With the 2100 series broach head it is essential to use the
correct length broach. The overall length of the broaching bit is 28mm +0,30 -0,0
and the shank diameter is 8mm with an h5 tolerance. Failure to use the correct
8h5
length broach and hitting the bottom of the hole will result in poor broach quality,
corners chipping on the tool and damage to the bearing or head. +0,30
28 -0,00

27,5 min after

Re-sharpening
Series 6100 and 26000
PCM broaching holder series 6180, 6190, 26200 and 26300 are delivered adjusted within .0006 for our standard tools
with a 55mm +0.3 length. When tools with different length are used, it is essential to re-adjust the exact centering
position. Experience has proven that turret bores are not in perfect alignment with the machine spindle after a certain
working time. When misalignment is over .002 of an inch it is necessary to re-adjust the turret positioning to avoid
broaching difficulties especially on small sizes.

5 Adjusting screws

Pre-Setting for exact centering: .0008

Set the indicator tip (5) on the gage pin (4) at the
correct L. Rotate the holder shank (2) in the preset
fixture (1) to obtain a max. TIR of .0008. (Notice
the oscillation of the gage pin as it rotates with the
2
holder)

Adjust the position using the 4 adjusting screws and

upon completion clamp the head tight with the 4 1
clamping screws; check again after clamping. 3
L

Clamping Screws

Adjusting Center On The Machine:

Adjustment on the machine offers the advantage to
5 Adjusting screws correct misalignment between the machine spindle
and the turret bore. The main inconvenience is the
.0008 adjustment is only valid for that one turret position.

With the gage pin (4) set to the proper L, set the
Machine broach head in the turret station (1) to be used for
Spindle
2
broaching. Set the indicator (5) on to the spindle
Centerline chuck with a magnetic base. Place the indicator tip
on to the end of the gage pin. Rotate the chuck so
4 the indicator sweeps the diameter of the pin.
L 3 1
Adjust the position using the 4 adjusting
screws and upon completion clamp the head
Clamping Screws tight with the clamping screws; check again
after clamping.

G:\Genevieve\Marketing & Products\Broaching\Use recommendations for broaching operations.doc