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What is horizontal broaching machine

What is horizontal broaching?

Horizontal broaching is a common industrial manufacturing technique used to produce precision components at rapid speeds. What is horizontal broaching machine If you need large quantities of specialty parts, or are considering changing the type of broaching machine you currently use, Miller Broaches can help. Find out how key services from a leading broaching company can save you time and money.

Types of broaching machines

Depending on the exact part specification, several types of broaching are available. Your work area and the type of cuts required to create your finished product determine the best broaching machine for your manufacturing needs. Here are some types of broaching machines to consider:

  • Horizontal broaching
  • Vertical broaching
  • Internal broaching
  • External broaching
  • Rotary broaching
  • Linear broaching

Many of these broaching types may overlap. For example, many horizontal broaching machines are designed for rotary broaching or pull broaching. While horizontal machines were more popular, vertical machines were often used as a space-saving option.

Vertical broaching machines offer results with a dramatically smaller footprint. If space is at a premium, this can be an attractive option. However, vertical broaching machines are limited in their stroke length depending on the height of your facility. Although a vertical broaching machine should have sufficient clearance for most applications, extra long strokes require a larger horizontal machine.

Of course, these are the basic types of broaching machines. These moving machines come in various sizes and features, and special broaching machines are available for individual cuts for special parts.

Materials suitable for broaching

Materials suitable for broaching

Broaching can be used to remove material from parts made from a variety of materials, including:

  • Steel
  • Copper
  • Aluminum
  • Graphite
  • Cumulative
  • Brass
  •  Bronze
  •  Tree

Origin of broaching

They are used to make pulleys and gears in the mid-1800s. In the early 1900s, it was used to make barrels for guns. Today, broaching is used to make everything from small fasteners to automotive transmission gears, aircraft parts, and more.

Advantages and Disadvantages of Broaching

The main advantage of broaching is that it is capable of creating odd-shaped holes in the workpiece with extreme precision. If round holes are required, an alternative machining process may be used. However, for hexagons and other odd shapes, broaching is the correct process for the job.

Broaching machines, on the other hand, are very expensive, typically costing thousands of dollars. And apart from broaching machines, manufacturing companies also need to invest in broaches. If the process is used to create a specific shape for a specific workpiece, a custom broach should be used. Custom brooches alone can cost several hundred dollars.

Linear vs. Rotary Broaching: What’s the Difference?

Broaching processes can be classified as linear or rotary depending on the position of the broach. With linear broaching  the most common type of broaching process broaching is applied linearly to the part. With rotary broaching, the broach rotates as it presses against the workpiece.

Horizontal broaching features

Depending on the type of machine, horizontal broaching machine can be used for drawn, continuous, rotary and surface broaching. Compared to vertical machines, a horizontal broach machine is capable of combining longer strokes.

Broaching machines are described in terms of tonnage and stroke range. For example, a horizontal broaching machine might have a force of six tons and a stroke of 48 inches. Your workpiece will largely determine the size and specifications of the broaching machine needed, so many broaching services use multiple broaching machines for varying degrees of precision performance.

These broach machines can perform the first steps required for a finished product or make cuts ready for delivery. It is essential to use tools precisely designed for your exact workplace, otherwise you may end up spending extra time and energy on unnecessary activities. Once you get specialized equipment from a leading Broach specialist, you can enjoy continued use with minimal downtime for routine maintenance.

 Advantages of horizontal broaching

Compared to a vertical system, there are several advantages to choosing horizontal broaching. A horizontal machine offers a dramatic range of cutting sizes, especially for internal broaching. It can easily create squares, hexes, keyways and splines with extra long strokes.

Horizontal broaching machines are easy to repair and retool. Depending on the exact specifications of your broaching needs, there may be little or no costs associated with tooling when you use an industrial broaching service.

A horizontal machine can used to create external spaces, forms and outlines in your workspace. Because retooling is easy, horizontal broaching is capable of mass-producing a variety of specialty workpieces for your manufacturing needs.

 Find premier broaching services at Miller Brooches

Learn more about broaching services by contacting Miller Broaches. As a leading industrial broaching company, we offer a variety of broaching services to meet your needs. From retooling and rebuilding broach machines to high-quality production of broached workpieces, we have the skills needed to keep your company at the forefront of its industry. Contact us today to learn more about horizontal broaching and how you can use it to improve your manufacturing capabilities.

How Broaching Machines Work

Although it can done by hand, most manufacturing companies use a machine when breaking down workpieces. Usually powered by hydraulic pressure, broaching machines can used to hold and operate a broach – the cutting tool – that pushes or pulls it against the workpiece. However, there are many types of broaching machines, including horizontal and vertical. Vertical broaching machines can designed to push the broach against the workpiece, while horizontal broaching machines can designed to pull the broach through the workpiece. Although vertical broaching machines are the most common, statistics show that only one in 10 of all broaching machines purchased and used by manufacturing companies are horizontal broaching machines.

Methods of broaching

The classification of broaching methods is as follows:

  1. Pull broaching
  2. Bush broaching
  3. Surface broaching
  4. Continuous broaching
Broaching to pull

In pull broaching the work can fixed and the broach can pulled through the work. Usually, brooches are very long and can placed on a special head. The pull broaching method can used for internal broaching, but also for some surface broaching.

Push broaching

In push broaching the work can  fixed and the broach can pushed through the work. Manual and hydraulic arbor presses can commonly used for push broaching. This method can used to shape holes and cut keyways.

Surface broaching

In surface broaching the work or broaching tool passes over each other. This method has become the main means of surface finishing. Many irregular or complex shapes can carved by surface broaching, but tools must can specifically designed for each job.

Continuous broaching

In continuous broaching, the work continues continuously and the broach remains stationary. The movement of work can be straight, horizontal or circular. The continuous broaching method can often used to perform several similar jobs simultaneously.

Broaching machine operation

Broaching can used for machining various internal and external surfaces, for round or irregularly shaped holes with a diameter of 6 to 100 mm, external flat and contoured surfaces.

Certain types of surfaces, for example, spline holes, can currently machined only by broaching because of the extraordinary difficulties in machining such surfaces by other methods.

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Advantages and limitations of broaching

Features and benefits of broaching include:

  1. Production rate is very high.
  2. Skill can required from the operator to perform broaching operations. In most cases, the operator simply loads and unloads the workpiece.
  3. High precision and high quality surface finish possible. A tolerance of ±0.0075 mm in broaching and a surface finish of about 0.8 micron (1 micron = 0.001 mm) can easily achieved.
  4. Both roughing and finishing cuts can completed in one pass of the tool.
  5. Broaching process can used for internal and external surface finishing.
  6. Any shape or form reproduced in broaching may can machined.
  7. Because the broach draws the fluid into the cut, cutting fluid can easily applied where it can most effective.
Limitations of broaching

However, for specific reasons, limit the use of the broaching process. They are:

  1. High equipment costs. A brooch usually has only one function and expensive to make and sharpen.
  2. Very large pieces of work cannot broken.
  3. The surface to engraved must not have any obstructions.
  4. Broaching cannot used to remove excess stock.
  5. Parts to can broached must can firmly supported and capable of withstanding the forces applied during cutting. Readmore

 

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