Troubleshooting For Broaching Operation

Table of Contents

During long-term use of the broaching machine, various failures may occur. Here are some common broaching machine failures and their solutions:

1.The sliding seat does not move smoothly

Cause of failure
- It may be guide rail wear, insufficient lubrication or unstable hydraulic system pressure.
Solution
- Check the guide rails. If they are worn, repair them by grinding or replace them with new ones.
- Make sure the lubrication system is working properly and add or replace lubricating oil regularly.
- Check the hydraulic system and adjust the pressure to the appropriate range.

2. Tool vibration

Cause of failure
- The tool installation is unstable, the tool is unbalanced, or the cutting parameters are improperly set.
Solution
- Recheck and tighten the tool mounting location.
- Balance and adjust the tool to reduce vibration.
- Optimize cutting parameters and reduce vibration caused by cutting forces.

3. Processing accuracy decreases

Cause of failure
- It may be that the geometric accuracy of the machine tool is too poor, the tool is worn, or the processing parameter settings are unreasonable.
Solution
- Perform geometric accuracy testing and adjustment on machine tools to restore their original accuracy.
- Replace worn knives and make sure they are sharp and installed correctly.
- Reset reasonable processing parameters according to the workpiece material and processing requirements.

4. Hydraulic system leakage

Cause of failure:
- aging of hydraulic pipelines, loose joints or damaged seals.
Solution
- Replace aging hydraulic lines.
- Tighten loose connectors to ensure a secure connection.
- Replace damaged seals to prevent hydraulic oil leakage.

5. Electrical system failure

Cause of failure
- It may be aging of electrical components, short circuit or control system software problem.
Solution
- Check electrical components regularly and replace them in time if there are signs of aging.
- Check the line connection and eliminate short circuit fault.
- If there is a problem with the control system software, you can try to restart the system or contact a professional for repair.

6. Cooling system failure

Cause of failure
- Insufficient coolant, blocked cooling pipe or damaged cooling pump.
Solution
- Add enough coolant.
- Clean the debris in the cooling pipe to ensure smooth flow of coolant.
- Replace the damaged cooling pump and restore the cooling system to normal operation.

7. The broach stops during broaching

Reasons
- Insufficient power of the broaching machine, chip deposition or blade damage, changes in workpiece material deteriorating chip performance, and chip blockage.
Preventive measures
- Use a high-power broaching machine, regrind to remove deposits and damaged parts, replace the lubricant, check the composition and hardness of the workpiece, and remove chips.

8. Chatter occurs during broaching

Reasons
- The rigidity of the machine tool and fixture is insufficient, the workpiece elastically recovers after processing, the relationship between the tooth pitch and the chip length is out of balance, and there are too few edges participating in the chip.
Preventive measures:
- Increase the rigidity of the machine tool and fixture, increase the wall thickness of the workpiece, add back support to the broach, and check whether the workpiece is processed shorter than the specified length.

9. Workpiece broaching notch defect

Reason:
- The blade is damaged or bruised, and there is deposit on the blade.
Preventive measures:
- regrind to remove damage, replace broach

10. Broaching surface is not smooth

Reason:
- The blade is worn, there is deposit on the blade, and the chips scrape the surface of the workpiece.
Preventive measures:
- regrind to improve sharpness, remove chips, replace lubricant

11. Large burrs are produced on the broached surface

Reason:
- The change in workpiece material causes the cutting performance to decrease and the cutting sharpness to decrease.
Preventive measures:
- Check the material and hardness of the workpiece, and regrind to improve sharpness

Another Troubles and solutions in broaching operation

Trouble	Cause	Solution
The broach stops during cutting	Power shortage of broaching machine	Use broaching machine with enough power
	Increase of cutting resistance due to adhesion, tooth chip, and abnormal wear.	Remove adhesion, a tooth chip, and abnormal wear by regrinding. Change cutting oil.
	Deterioration of machinability because of quality change of work material	Check the composition, the structure, and the hardness of work material. Change cutting oil
	Chip stuck	Whether the workpiece of a specified cutting length or more is processed is checked, chip is completely removed
Generation of chattering vibration	Number of cutting teeth being too small, that can work simultaneously	Check whether the cutting length is not longer than it should be. Remove chip completely.
	Spring back phenomenon of workpiece	The wall thickness of the workpiece should be thickened
	Resonance due to pitch and cutting length	Support the rearend or modify the project of broach.
	Rigidity shortage of machine and clamping device	Repair the machine and modify the clamping device.
Tear of side face	Adhesion on the cutting edge side face	Remove the adhesion part by regrinding. Change cutting oil
A big burr generates	Deterioration of machinability because of quality change of work material	Check the composition, the structure, and the hardness of work material. Change cutting oil
A big burr generates	Deterioration of sharpness	Regrind to improve sharpness
Tear of contour	Due to wear of the tip of cutting edge, finishing surface wears off	Regrind to improve sharpness
	Adhesion on the cutting edge	Remove the adhesion part is excluded by regrinding. Change cutting oil.
	Chipping the cutting edge is caused on	Remove chipping part by regrinding.
	Scratch on the cutting edge	Remove the scratch by regrinding
	Chip and the work piece processing surface rub each other	Regrind to improve sharpness. Remove chip completely. Change cutting oil
Thread streak	Chipping is caused on cutting edge chipping	Remove chipping part by regrinding
	Scratch on the cutting edge	Remove the scratch by regrinding
	Adhesion on the cutting edge	Remove the adhesion part by regrinding. Change cutting oil
Breakage and tooth lack	Broach installation is not good	Improve the installation
Breakage and tooth lack	Chip stuck	Check whether the cutting length is lot longer than it should be. Remove chip completely Change cutting oil
The go gauge does not enter	Eccentric of processing hole	Remove chipping part and scratches on the broach cutting edge if there is any. The standard surface and prepared hole should be correctly processed
	The corner part of the cutting edge wears out abnormally	Regrinding to remove the wear part
	The finish size is smaller than the allowance lower bound	Regrinding to improve sharpness. The wall thickness of the workpiece should be enlarged.
The no gauge passes	Large burr when the tooth face is ground	Remove burr from the cutting edge.

Through the above introduction to common faults and solutions of broaching machines, you can better deal with the problems encountered during the use of the equipment. In actual operation, please be sure to follow safe operating procedures and perform regular maintenance on the equipment to ensure the stable operation and processing quality of the broaching machine.