The working principle of the broaching machine is to use the spindle to fix the workpiece, and then through the forward and backward rotation, the purpose of stretching the workpiece is achieved. The following are the working principles of broaching machines and the characteristics of broaching:
How the broaching machine works ?
The broaching machine mainly consists of a machine bed, spindle, oiler, front bar, tailstock, cutter, cutting fluid, etc. The spindle is the core component of the broaching machine.
It can move forward and backward along the bed to control the feed and retraction of the workpiece. When the broaching machine is working, first fix the workpiece on the spindle, then press the clamp on the front cooler against the workpiece, tighten the chuck, start the spindle and rear cooler, and start the workpiece to rotate. During the machining process, the spindle moves along the bed to control the feed and retraction of the workpiece, and ultimately realizes the stretching process of the workpiece.
Characteristics of broaching
- High efficiency: The broach is a multi-tooth tool. There are more teeth working at the same time, which increases the total cutting width. The broach can complete roughing, semi-finishing and finishing processes in one stroke, which greatly shortens the cutting time. Basic process time and auxiliary time
- High precision and low surface roughness: Broaching speeds are generally low and the cutting thickness of each cutting tooth is small, so the cutting process is smooth and the adverse effects of built-up edge can be avoided. Broaching can achieve higher precision and lower surface roughness
- Wide processing range: Broaching can not only process flat surfaces and unobstructed outer surfaces, but also process through holes of various shapes, so broaching has a wide processing range
8 Steps How to Use a Broaching Machine Effectively
1.Comprehend the fundamental framework and operations of broaching machines
Prior to utilising a broaching machine, it is crucial to possess a comprehensive comprehension of its structure and operations.
The broaching machine consists mostly of a bed, a slide, a tool rest, and a tailstock. This machine is specifically engineered to process the outside circumference, inner bore, and end face of the workpiece.
Furthermore, it is important to comprehend several categories of broaching machines, such as horizontal and vertical broaching machines, along with their respective suitable situations.
2. Inspect the equipment
- Inspect the power supply and switch of the broaching machine to verify the stability of the power connection and the flexibility and reliability of the switch operation.
- Inspection of mechanical components: Inspect each component, including the bed, slide, tool rest, and other crucial parts, individually to ensure there is no looseness, damage, or unusual wear.
- Inspection of hydraulic system: Verify if there are any leaks in the hydraulic pump, oil cylinder, oil circuit, and other components. Additionally, ensure that the hydraulic oil level is enough and that the hydraulic system pressure is within the usual range.
- Lubrication system inspection: Inspection of the lubrication system involves verifying the proper functioning of the lubrication pump, oil nozzle, and other components, as well as ensuring that the channel for the lubricating oil is free from any obstructions.
3. Clamping the workpiece
- Choose the fixture: Choose the suitable fixture according to the shape, size, and processing needs of the workpiece.
- Mount the workpiece: Gently position the workpiece onto the fixture, providing a snug and stable fit without any movement.
- Secure the fixture: Utilise a wrench or an alternative specialised tool to securely fasten the fixture onto the broaching machine, ensuring that the workpiece remains stationary during the processing procedure.
4. Adjust the tool
- Choose the tools: Choose the suitable tool category and parameters according to the material of the workpiece and the processing needs.
- Proceed with the installation of the tool: Properly install the tool onto the tool holder and make necessary adjustments to ensure that the tool is positioned and angled appropriately in relation to the workpiece.
- Inspection of tool accuracy: Utilise precision measuring instruments, such as a dial indicator, to assess the radial runout and axial displacement of the tool. This is done to verify that the tool’s precision aligns with the necessary processing specifications.
5. Set processing parameters
- Setting cutting parameters: Determine appropriate values for cutting speed, feed rate, and back engagement depending on characteristics such as workpiece material, hardness, and processing needs.
- Adjustment of the rotational speed of the spindle: Optimise the broaching machine spindle speed based on the cutting parameters and tool type to get the most effective cutting outcome.
- Hydraulic system pressure adjustment: Modify the hydraulic system pressure based on the complexity of the workpiece processing and the load on the tool to guarantee the stability and dependability of the processing procedure.
6. Start processing
- Start the equipment: Turn on the power of the broaching machine and let the spindle rotate to the set speed.
- Operating the hydraulic system: By operating the handle or button, the slide is controlled to move along the bed, driving the tool to accurately cut the workpiece.
- Monitor the processing process: Pay close attention to changes in chip shape, color, temperature, etc. during the processing process to adjust processing parameters in a timely manner to ensure processing quality.
7. End processing and clean up the site
- Stop the equipment: When the workpiece is processed, turn off the broaching machine spindle and hydraulic system and disconnect the power supply.
- Unload the workpiece: Remove the processed workpiece and conduct comprehensive measurement and strict inspection to ensure that it meets quality standards.
- Clean the site: Use special tools to clean chips, coolant and other dirt on the broaching machine to keep the equipment and working environment clean.
8. Care and maintenance
- Regular inspections: Regularly conduct comprehensive inspections of the broaching machine, including mechanical components, hydraulic systems, electrical systems, etc., to discover and deal with potential problems in a timely manner.
- Lubrication and maintenance: According to the requirements of the equipment manual, perform regular lubrication and maintenance on the broaching machine to ensure that all moving parts are fully lubricated and extend the service life of the equipment.
- Electrical system maintenance: Regularly clean the dust and debris in the electrical control cabinet, check whether the electrical components are aged or damaged, and ensure the stable operation of the electrical system.
- Records and backups: Establish equipment care and maintenance files, and record the time, content and results of each maintenance in detail for future review and reference.
With the expanded step-by-step guide above, you will be able to more fully grasp how to effectively use a broaching machine for workpiece processing. In actual operation, please be sure to strictly observe the safety regulations to ensure personal and equipment safety.
Maintenance of broaching machine
The maintenance of a broaching machine is an important part of ensuring its long-term stable operation and processing accuracy. Here are some basic maintenance tips
Daily maintenance
- Check the coolant and lubricating oil: Make sure there is enough oil in the coolant tank and the oil reservoir of the lubricating pump, and replenish it in time if it is insufficient.
- Lubricate the machine tool: Before each use, let the main slide reciprocate several times to ensure that the screw, mother wire and bearings are lubricated in place.
- Check the power distribution cabinet and lubrication system: Confirm that the fan motor of the power distribution cabinet is running normally, and that the lubrication and air source pressure gauges are in normal working condition.
- Clean the machine tool working area: Clean the machine tool working area every day, and clean the cutting tools, brushes, flanges, main and auxiliary chuck bodies, and iron filings on the workbench before leaving get off work or changing shifts.
Quarterly maintenance
- Mechanical maintenance: including cleaning or replacement of the dustproof plate of the main slide plate, inspection of guide rail wear, confirmation of the fixed connection of the main chuck body, etc.
- Electrical maintenance: Clean or replace the cooling filter of the power distribution cabinet, clean the motor fan blades, confirm the sensor switch connection port, etc.
- Lubrication maintenance: Confirm the lubrication pump pressure, check the lubrication pipeline, confirm whether the main slide lubrication is clogged, etc.
- Water tank, chip conveyor, and oil temperature control maintenance: water tank filter cleaning or replacement, chip conveyor chain inspection and adjustment, oil temperature control filter cleaning, etc.
Annual maintenance
- In-depth maintenance: including cleaning the cooling box, replacing the filter, cleaning the lubricating oil tank, adjusting the chain magnet of the chip conveyor, etc.
- Comprehensive inspection: Conduct a comprehensive inspection of the broaching machine, including replacing the main slide plate, auxiliary slide plate and ball screw lubricant, checking whether the oil pipes and joints are blocked, etc.
- Machine tool geometric accuracy detection: Test the machine tool geometric accuracy to ensure machining accuracy
Through the above maintenance measures, the service life of the broaching machine can be effectively extended and its good processing performance can be maintained.
Read More: Troubleshooting For Broaching Operation
What safety matters need to be paid attention to when operating a broaching machine?
Safety is the primary consideration when working with a broaching machine. Here are some key safety considerations to keep you and your colleagues safe:
- Operator qualifications: Operators must be proficient in the operation essentials and technical performance of the broaching machine, and can only work after passing the assessment.
- Equipment inspection: Before starting the machine tool, you must carefully check whether the oil in the hydraulic oil tank and coolant tank is sufficient to ensure that the hydraulic oil does not contain harmful impurities such as condensation, acid, alkali and moisture.
- Lubrication and cleaning: All lubrication parts must be carefully lubricated according to the requirements of the lubrication chart. At the same time, keep the workbench and machine tool guide rails clean and avoid stacking knives, tools and other items
- Preparation before operation: Before each use, the main slide must be allowed to reciprocate several times when empty, and the bleed plug near the pressure gauge must be slightly loosened to remove the air in the cylinder to prevent the main slide from crawling.
- Precautions during processing: During the broaching process, if the system pressure decreases, the maintenance worker should be notified immediately for repair. The broach should be handled with care to prevent the broach from breaking.
- Handling of emergencies: Operators should stop the machine immediately if they find equipment failure, report it to the workshop and equipment department for maintenance in a timely manner, and it is strictly prohibited to work while sick.
By following the above safe operating procedures, you can minimize the risks when operating a broaching machine and ensure the safety of personnel and equipment.
How To Choose The Right Broaching Machine For Your Needs?
Ultimately, it is essential to ensure that you select the appropriate broaching equipment that meets your specific requirements. Several considerations should be taken into account while making your selection, including the material type to be broached, the size of the workpiece, and the required level of accuracy. Here are few variables to consider while selecting a broaching machine.
1.Material composition
The composition of the material you will be broaching is a crucial thing to take into account. It is essential to ensure that the machine is specifically engineered to be compatible with the material you intend to use. For instance, if you intend to work with aluminium, it is necessary to use a machine that is explicitly engineered for aluminium.
2. The dimensions of the workpiece
Another factor to consider is the size of the workpiece. It is important to ensure that the machine is capable of accommodating the dimensions of the workpiece. If you are dealing with a substantial workpiece, it may be necessary to select a machine of greater size.
3. The precision
Precision is a crucial aspect to take into account when selecting a broaching machine. Certain materials need a greater level of accuracy compared to others. For instance, when dealing with a pliable substance, a machine with less precision may suffice compared to one specifically developed for a more rigid material.
4. Velocity
Velocity is a crucial factor in determining the efficiency of the broaching operation. When selecting a machine, ensure that it possesses the appropriate velocity to meet your requirements. Utilising more efficient machinery enables you to do the task at a faster pace.
5. The Power
Power is a crucial aspect in the realm of broaching machines. High-performance machines have the capability to process more challenging materials and accommodate bigger workpieces. If you want a machine capable of managing a substantial workload, it is advisable to get a machine with greater power.
6. Warranty
The warranty should be taken into account when selecting a broaching machine. Ensure that the equipment is accompanied with a robust guarantee to facilitate repair or replacement in the event of any malfunctions.
Read More: How To Choose The Right Broaching Machine
Conclusion
Using a broaching machine can be a great way to remove material from a workpiece. However, it is important to use the machine safely and to choose the right type of machine for your particular needs. We at BroachingMach believe this guide has been useful in providing you with the information that you need to use a broaching machine effectively.