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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. [20]
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]
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.
The works would have one large steam engine which would provide power to all the machines via a line shaft system of belts. Therefore, early engine lathes were generally 'cone heads', in that the spindle usually had attached to it a multi-step pulley called a cone pulley designed to accept a flat belt. Different spindle speeds could be obtained ...
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.
A metal lathe is an example of a machine tool. A machine tool is a machine for handling or machining metal or other rigid materials, usually by cutting, boring, grinding, shearing, or other forms of deformations. Machine tools employ some sort of tool that does the cutting or shaping.
The Jacobs Rubber-Flex brand is a name that most machinists would recognize for this type of collet chuck system. Regardless of the collet design, the operating principle is the same: squeeze the collet radially against the tool or workpiece to be held, resulting in high static friction. Under correct conditions, it holds quite securely.
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