1. Broaching & Sawing Processes
Instructor - Sam Chiappone

2. Broaching
Broaching is the process of removing metal with a tool which has “teeth” arranged in a row. Each tooth is successively higher than the previous tooth and removes more material. In broaching, one stroke or cycle of the machine produces a finished part.
Broaching is used to produce both internal and external features. Production rates are high and tolerances of +/ ” are possible.

3. Broaching

4. Broaching

5. Broaching

6. Broaching Chip Formation
Chip formation involves three basic requirements:
The cutting tool must be harder than the part material
There must be interference between the tool and the part as designated by the feed rate and cut per tooth
There must be a relative motion or cutting velocity between the tool and workpiece with sufficient force to overcome the resistance of the part material.

7. Broaching Tool Feed Direction Tool Gullet Depth of cut per tooth
Workpiece

8. Broaching Chip Formation
As long as these three conditions exist, the portion of the material being machined that interferes with the free passage of the tool will be displaced to create a chip.
Many combinations exist that may fulfill such requirements.
Variations in tool material and tool geometry, feed and depth of cut, cutting velocity, and part material have an effect not only upon the formation of the chip, but also upon cutting force, cutting horsepower, cutting temperatures, tool wear and tool life, dimensional stability, and the quality of the newly created surface.

9. Broaching The Mechanics of Chip Formation
Empirical metal-cutting studies reveal several important characteristics of the chips formed during the broaching process:
The cutting process generates heat
The thickness of the chip is usually greater than the thickness of the layer from which it came
The hardness of the chip is usually much greater than the hardness of the parent material, and
The other three relative values are all affected by changes in cutting conditions and in properties of the material to be machined

10. Broaching The Mechanics of Chip Formation
These observations also indicate that the process of chip formation is one of deformation or plastic flow of the material, with the degree of deformation dictating the type of chip that will be produced.

11. Broaching Plastic Deformation
Originally, it was thought that chips formed in metal cutting were created in much the same way that wood chips are formed when split by an axe. This may be partially true for brittle materials such as cast iron, but it does not hold true for the majority of metals. The process by which chips are formed with metal-cutting tools is called plastic deformation, and was first described by Rosenhain at the Stratsfordshire Iron and Steel Institute in 1906.

12. Broaching Plastic Deformation
What actually happens in this shearing process is that the metal immediately ahead of the cutting edge of the tool is severely compressed resulting in temperatures high enough to allow plastic flow.
When the resisting stresses in a material exceed their elastic limit, a permanent relative motion occurs and further deformation is withstood.
This strengthening is called work or strain hardening, and is characteristic of all steels, but demonstrated most dramatically in stainless steels.

13. Broaching How and Where Heat is Generated
The force or energy that is put into the tool creates movement in a group of metal atoms in the workpiece. This group is a finite number of atoms which are forced to change their positions in relationship to each other.
As the atoms in the metal ahead of the tool are disturbed, the friction involved in their sliding over one another is thought to be responsible for 60% or more of the total heat generated.
This internal friction, and the heat it generates, can be compared to the friction and heat caused by bending a paper clip back and forth until it breaks.

14. Broaching How and Where Heat is Generated
As the tool continues to push through the work piece, a chip eventually slides up the cutting face of the tool. This sliding creates an external friction which again releases heat. This external friction accounts for about 30% of the total heat generated.
The third area of heat generation is on the land or flank of the tool. This area accounts for about 10% of the heat generated. This is assuming that the tools are sharp and made correctly as far as clearance angles and face angles are concerned. As the tool wears, the above percentages will vary, especially when there is excess wear on the land, or if the clearance angle is insufficient for the material or the part configuration. This contact zone will actually increase as the part continues to close in after the cut resulting in extremely high pressures on the land area of the tool.

15. Advantages & Disadvantages
Rough to finish in one pass
Production rates are high
Cutting time is quick
Rapid load and unload of parts
External and internal features
Any form that can be produced on a broaching tool can be produced
Production tolerances are excellent
Surface finishes are equal to milling
Operator skill is low

16. Advantages & Disadvantages
Tooling cost can be high
In some cases--not suited for low production rates
Parts to be broached must be strong enough to withstand the forces of the process
Surface to be broached must be accessible

17. Methods of Operation
Pull broaching - broach is pulled through or across stationary work
Push broaching - broach is pushed through or across work
Surface broaching - either the work or the broach moves across the other
Continuous broaching - the work is moved continuously against stationary broaches. The path of the movement may be straight or circular.

18. Machines
Vertical single and double slide - Table moves part into position for broaching, part is broached and the table retracts for unloading.
Vertical push broaching - Used for internal features such as holes, rounds, or slots.
Vertical pull down
Tool is suspended above work
Lowered into pull mechanism in the base of the machine
Advantages
Part positioning is easy
Large parts are handled efficiently

19. Machines
Vertical single and double slide

20. Machines
Horizontal
Versatile machine capable of producing internal and external features
key-ways
gear teeth
riffling
High cutting speeds in the range of 10-40ft/min with return speeds of 110 ft/min
MRR of ¼ in per stroke is possible

21. Methods of Operation

22. Machines
Horizontal

23. Machines
Rotary
Parts are mounted to a rotating table and are moved to different stations for different operations
Primarily used on small parts
Typical operations include:
Slotting
Holes
Key-ways

24. Broaching Tools Design & Construction
Considerations
Material to be broached
Size and shape of cut
Quality of surface finish
Part tolerance
Productions rates
Type of machine
Workholding method
Strength of the workpiece

25. Sawing
Depending on part tolerance, sawing can be a vital first operation or the total process.

26. Machines Classifications
Reciprocating saws
Horizontal hacksaw and vertical sawing machines
Light to heavy duty
Simple and most economical to operate
Manual to fully automatic feed mechanisms
Uses blades similar to hacksaw blades

27. Machines Classifications
Circular saws
Sometimes called cold sawing machines
Saw blades are large and rotate at low Rpms
Cutting is similar to a milling operation due to geometry of saw blade

28. Machines Classifications
Band saws
Irregular shapes
Very versatile
Profile cuts
Internal cuts
external configurations
Blades are continuous
HSS - Carbide tipped
Diamond impregnated
Filing

29. Machines Classifications
Band saws 2 1 3

30. Saw Blades
Circular
Straight
Band

31. Saw Blades Terminology
Set of the blade - Directional offset, left-right, from the blades centerline. Sometimes referred to as the “kref.” The kref provides clearance for the blade as it cuts through the work.
Straight - one tooth left one tooth right. Typically used for brass, copper, and plastic.
Raker - Three tooth sequence, left, right, straight. Typically used for steel and cast iron.
Wavy - Alternate arrangement of several teeth to the right and left. Used to cut tubes and light sheet metal.

32. Saw Blades

33. Saw Blades
Tooth forms
Variable positive
Variable
Standard
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