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Broaching is often impossible without the specific broaching or keyway machines unless you have a system that can be used in conjunction with a modern machining centre or driven tooling lathe; these extra bits of equipment open up the possibility of producing keyways, splines and Torx through one-hit machining.
There are three main steps in broaching a keyway: First, the workpiece is set on the arbor press and the bushing is placed in the opening of the workpiece. Next, the broach is inserted and pushed through, cutting the keyway. Finally, shims are placed between the bushing and the broach to achieve the correct depth necessary for the key. [6]
Gear cutting is any machining process for creating a gear.The most common gear-cutting processes include hobbing, broaching, milling, grinding, and skiving.Such cutting operations may occur either after or instead of forming processes such as forging, extruding, investment casting, or sand casting.
Broaching is a machining operation used to cut keyways into shafts. Electron beam machining (EBM) is a machining process where high-velocity electrons are directed toward a work piece, creating heat and vaporizing the material. Ultrasonic machining uses ultrasonic vibrations to machine very hard or brittle materials.
Broaching can refer to two operations, linear broaching, where a multi toothed tool is pressed through a hole to cut a desired shape (e.g. a spline, square, or hex shape) or along a surface by taking increasingly larger cuts by the increasing sized teeth of the broach; or rotary broaching, where a drafted tool is rotated in a special toolholder ...
Rotary broaching is another common operation. The broach holder is mounted stationary while its internal live spindle and end cutting broach tool are driven by the workpiece. As the broach is fed into or around the workpiece, the broach's contact points are constantly changing, easily creating the desired form.
Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The process is rapid and produces fine surface finish with high dimensional accuracy. However, because broaches are expensive and a separate broach is required for each size of gear, this method is suitable mainly for high-quality production.
Spindle nose on a lathe headstock. The small female taper is a Morse taper to take a lathe center or a tool such as a twist drill. The large male taper takes a lathe chuck, which is retained by the large nut. A machine taper is a system for securing cutting tools or toolholders in the spindle of a machine tool or power tool.