Broaching is one of the most precise and productive processes in metalworking areas. In this process removal of a layer of material of desired width and depth usually in one stroke by a slender rod or bar type cutter having a series of cutting edge. It can be performed on a broaching machine. Let us have a deep insight into the pros and cons of the broaching process.
Advantages of broaching :
- Very high production rate higher than milling, planing, boring etc.
- High dimensional and form accuracy and surface finish of the product.
- Roughing and finishing in a single stroke of the same cutter.
- Needs only one motion of cutting, so design, construction, operation and control are simpler.
- Extremely suitable and economical for mass production.
- Expertise not needed.
- Remarkable finished face.
- Short cycle time with high accuracy.
- Little skill is required to perform a broaching operation.
- Broaching can be used for either internal or external surface finishing.
- A tolerance of +-0.0075 mm and a surface finish of about 0.8 microns can be obtained in this process.
- Cutting fluid may be readily applied where it is most effective because a broach tends to draw the fluid into the cut.
Disadvantages of broaching :
- Only through holes and surfaces can be machined.
- Usable only for light cuts.
- Cutting speed cannot be high.
- Defects or damages in the broach severely affect product quality.
- Design, manufacture and restoration of the broaches are difficult and expensive.
- Separate broach has to be procured and used whenever size, shape and geometry of the job changes.
- Economic only when the production volume is large.
- A very large workpiece can not be broached.
- High tool cost.
- Broaching can not be used for the removal of a large amount of stock.
- Parts to be broached must be capable of being rigidity supported and must be able to withstand the forces that set up during cutting.