One type of milling machine uses a broach, which is a special tooling device used to remove material during cutting operations. A broaching machine houses this special tool. This type of machine is used primarily for cutting unusual shapes and sizes. It is an efficient way to perform this type of milling operation because it generally does the job in only one pass. This keeps shop production at its peak performance, especially during large production runs.
A broaching tool looks very much like a saw, with the height of the teeth increasing along the length of the tool. This is referred to as RPT, or rise per tooth. A broach is made up of three parts: one for roughing, another for semi-finishing and one for the final finish work. The broach and the work piece work efficiently together in a non-complex manner. There is no skilled expertise needed to operate the machine because it works primarily on its own once everything is in place.
Almost all broaching machines are hydraulic but there are some that are mechanically driven. There are horizontal and vertical models and the one chosen depends on what the stroke requirements are. Vertical machines generally have a stroke that is less than 60 inches and are used for pull-down or pull-up broaching, surface broaching and push broaching. On the other hand, horizontal machines are usually used for surface and pull broaching as well as continuous and rotary broaching. Horizontal machines are not nearly as popular today because they are larger and more cumbersome than their vertical “cousins”.
Broaching can be a very simple process. Surface broaching simply is the process of using a fixed broach in conjunction with the work piece. Internal broaching is a little more complicated because the work piece must be clamped into the machine or the work piece must be aligned to the broach. No matter what process is used, it is important that fluids are used. Fluids cool the work piece and also the broach. They are also used to provide lubrication to the surfaces that are going to be cut. Finally, broaching machine needs fluids to rid the teeth of debris and chips.
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