11 June 2017

Advantages and disadvantages of broaching

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.