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Modular broaches are commonly used for large internal broaching applications. They are similar to shell broaches in that they are a multi-piece construction. This design is used because it is cheaper to build and resharpen and is more flexible than a solid design. [14] A common type of internal broach is the keyway broach (C & D).
Broaching is primarily used to cut square cornered internal keyways. The specific broach, bushing and guide are used for each given keyway cross-section, which makes this process more expensive than most of the alternatives. However, it can produce the most accurate keyway out of all the processes.
Often, with internal splines, the splined portion of the part may not have a through-hole, which precludes use of a pull / push broach or extrusion-type method. Also, if the part is small it may be difficult to fit a milling or grinding tool into the area where the splines are machined.
Keyways in the hub of a pulley or gear can be machined without resorting to a dedicated broaching setup. Dovetail slides; Internal splines and gear teeth. Keyway, spline, and gear tooth cutting in blind holes; Cam drums with toolpaths of the type that in CNC milling terms would require 4- or 5-axis contouring or turn-mill cylindrical interpolation
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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 ...