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Broaching and Broach Design
Published in Zainul Huda, Machining Processes and Machines, 2020
Broaching is a machining operation that involves the removal of metal by use of a multipoint cutting tool with teeth arranged in a row. The broaching machine tool is called a broaching machine, and the broaching cutting tool is called a broach. In broaching, the broach moves linearly relative to workpiece in the direction of broach axis. The teeth in the broach are so arranged that each tooth is successively higher than the previous tooth. Broaching enables us to broach internal or external surfaces. Figure 9.1a illustrates broaching for internal work shape; here the internal (round) broach is inserted into a pilot or starting hole which is made on the workpiece before machining. The broaching operation for external surfaces is shown in Figure 9.1b. A simple manual broaching job, such as cutting a keyway in a part, requires only a broach, an arbor press, and the appropriate fixtures. However, production broaching requires specialized broaching machines and is suitable for a large number of parts.
Design for Machining
Published in Helmi Youssef, Hassan El-Hofy, Non-Traditional and Advanced Machining Technologies, 2020
Broaching usually requires high-volume production that justifies the initial cost of the broaching tools and the need for a special machine. However, it can be applied when there is no machining alternative or when standard broaching tools are available. Production rate ranges from 15 to more than 100 times higher than with alternative machining methods. Tooling a machine for more than one part or for a group of similar parts with the same machined surface makes broaching an economical choice for small-lot quantities.
Lubricants for Near Dry Machining
Published in Leslie R. Rudnick, Synthetics, Mineral Oils, and Bio-Based Lubricants, 2020
Broaching is a precision machining operation where a broach can be pulled or pushed through a workpiece opening or over its surface to produce an exact shape. A broach can finish an entire surface in a single pass as opposed to milling. Internal or external shapes can be cut using broaches.
Big data and reliability applications: The complexity dimension
Published in Journal of Quality Technology, 2018
Yili Hong, Man Zhang, William Q. Meeker
In some applications measurements are taken over a spatial region for a period of time, which is related to the degradation process. We call this type of data “spatio-temporal degradation data.” For example, infrared cameras can be used to track the change in a thermal field. Although it is not directly related to degradation, vibrothermography data from Gao and Meeker (2012) in Figure 4 illustrate the evolution of a process over a two-dimensional spatial region. From frame 8 one starts to see a signal in the middle of the region, and the signal becomes evident in frame 16. Another example of spatio-temporal degradation is available in Liu, Yeo, and Kalagnanam (2018), who proposed to use spatio-temporal models to describe such types of data. They addressed challenges related to spatial heterogeneity, the spatial propagation of degradation to neighboring areas, and the anisotropic and space-time nonseparable covariance structure in a complex spatio-temporal degradation process. Other examples where spatio-temporal degradation data were generated include the spatial variation of a thermal field and the microscopic characterization for the wear of tools. In silicon ingot manufacturing, equipment degradation will affect the spatial variation of the thermal field, and a change in the thermal field will affect the quality of the ingot. In a broaching process, the condition of the broaching tool has a big impact on the quality of the final part. Images from a microscope are used to characterize the wear of the broaching tool over time.
Production data evaluation analysis model: a case study of broaching machine
Published in Journal of the Chinese Institute of Engineers, 2021
Chun-Min Yu, Kuen-Suan Chen, Yun-Yu Guo
To increase processing efficiency, broaching machines were designed to cut the workpiece surface in one pass. Broaching a workpiece with high precision requires the right machine parameter settings and the coordination of good broaches and fixtures. The table-up broaching machine employed in this study adopts multiple advanced technologies and processes to make up for the deficiencies of traditional hydraulic broaching machines. In addition, it has variable speed and 20% less energy consumption, and all of the parts in the production equipment adhere to lean manufacturing principles. There is no excess waste, no addition of unnecessary processes, and less recycle oil used, thereby achieving environmental protection.
Experimental investigation of dry and cryogenic broaching of AISI 4340 steel
Published in Materials and Manufacturing Processes, 2020
A. Navukkarasan, M. Pradeep Kumar, C. Chandrasekhara Sastry
The microhardness of the broached component is significant as the quality of the broaching cycle is dependent on the strength of the final-machined workpiece. This is evaluated by Tukon/Wilson 1102 – Vickers (scale: microns), with deadweight loads of 0.01–1 kg and 2 kg options.