Rotary broaching, also known as wobbling broaching, is a unique, quick, fantastic, and exact method of creating internal and exterior polygon forms on the end of a workpiece. The conventional broaching method entails inserting successively larger polygonal or other shapes into a hole until the desired form size is attained. By cutting the entire form, one corner at a time, rotary broaching can accomplish this in a single pass, frequently removing the need for a subsequent operation. This process works incredibly well on machines with horizontal or vertical spindles such as lathes, mills, etc. Read More…
Rotary BroachingRotary broaching is a process that involves spinning a broach on an automatic lathe. Rotary broaching requires less force than punching. It is also time efficient, as it only takes a few seconds to complete each part. Rotary broaches are used to make medical fasteners, splines and keyways.
With over 40 years of broach building experience, we have become specialized in manufacturing and engineering of broach tools in many shapes and sizes. Our manufacturing department has complete in house broach building capability. We provide broach manufacturing and reconditioning.
With 50 years of broaching experience, we have become specialized in manufacturing and engineering of broaches in many shapes and sizes. Our production machining department has complete machining skills. We provide specialized turning, machining, broach manufacturing and reconditioning.
Our capabilities include broaching services; id spur gear broaching; straight-sided and involute spline broaching; keyway broaching; serration and rotary broaching; internal broaching; horizontal/vertical broaching; sharpening and production broaching. We’re the sister company of G&G Manufacturing Co.
ISO-Certified, we’re known for superior quality, competitive pricing, & fast delivery. We specialize in low and high volume broaching of small and large parts out of almost any material. We design, engineer, & manufacture custom broach tools to meet your precision requirements. Contact us today for cost-saving tool maintenance programs such as reconditioning and re-sharpening of your broach...
Internal polygon structures can be quickly and precisely created using the rotary broaching technique. The entire process can be finished in a matter of seconds, and forms can be produced with an accuracy of at least 0.0005′′. Rotary broaching has become more and more popular as a result of this cutting-edge engineering, particularly in the plumbing, automotive, aerospace and medical sectors. Rotary broaching is the best technique for inserting a polygon form into the end of a part without the requirement for a subsequent operation.
Requirements for the Rotary Broaching Process
Any turning machine can essentially be converted into a rotary broaching machine. All that is required are the following two pieces of equipment.
Rotary broach: The rotary broach is the cutting tool used to cut a specific shape into, or remove a specific area from, a workpiece.
Rotary broach tool holder: The rotary broach tool holder simply contains a mechanism that holds the broach in place and allows the spindle to rotate freely.
Machines That use Rotary Broaching
Here are some popular machines that are easily adapted to perform rotary broaching:
CNC lathe machines
Swiss lathe machines
Working Principle of Rotary Broaching
An internal live spindle within the rotary broach tool holder, holds an end-cutting broach tool. The internal live spindle and rotary broach of the rotary broach tool holder are positioned stationary on a lathe, screw, or other turning machine while the workpiece rotates around them. The rotary broach tool is driven by the workpiece, and as it cuts each corner of the form, its corners are constantly changing contact points with the workpiece, creating a wobbling-like effect.
In a milling machine, the rotary broach tool and the internal live spindle of the tool holder remain fixed while the body of the tool holder revolves with the machine spindle. Additionally, because the corners of the rotary broach tool are constantly changing their points of contact with the workpiece, this results in a wobbling-like motion. Up to 2 inches of aluminum, 1.5 inches of brass, and 1 inch of steel can be broached for form sizes. Numerous other materials and depths have been successfully rotary broached, therefore this should just be used as a point of reference.
The secret to this technique's success is the cutting tool's 1° angle to the midline of the workpiece. As the rotary broach is fed into the part to the necessary depth, it shears into the workpiece with a chisel or scalloping effect. The broaching tool is held in place by a live spindle in the rotary broach tool holder, which allows the spindle to rotate freely inside the tool holder. In a lathe, the spindle is propelled by contact with the rotating workpiece. There is not much setup needed because the rotary broach tool holders do not require adjustments. These holders have characteristics like sealed bearings (which don't need routine maintenance) and a hole for pressure relief that lets air and fluid through.
With rotary broaching, the broach is first inserted into the workpiece. Typically, a pilot hole is driven into the workpiece in order to properly introduce the broach in it. Then, the workpiece is rotated by the spindle. The broach holder then rotates causing the broach to wobble as it moves along the workpiece.
Cuts Each Corner Individually
Any turning machine can use the rotary broach tool. As it is fed into the workpiece, the spinning motion causes the broach to wobble from corner to corner and use all of the machine's power to cut just one corner at a time. As it is fed into the workpiece, the cutter travels in a helical pattern.
Rotary broaching yields extremely exact forms. Despite being held at a one-degree inclination, the incline is so modest that the finished product's dimensional correctness matches the cutting tool's dimensions. Normally, rotary broaches are produced with a +0/-.0005" tolerance.
Advice Regarding Rotary Broaching
In order to achieve the best results, it is suggested that the ideal forming depth for rotary broaching is up to 1.5 times the distance across flats, or the diameter of the inscribed circular profile. Once more, this is merely a point of reference. Deeper depths can be reached depending on the application.
Benefits of Rotary Broaching
Although squares and hexagons are the most common shapes produced, rotary broaching creates a variety of items with intricate forms (see below) or workpieces with exquisite designs at their ends with a great finished quality. It is typically employed to produce the mechanical parts required throughout the manufacturing process and is used elsewhere in limited applications. It can be utilized on a variety of common materials such as plastic, cast iron, aluminum, and stainless steel; it can be used with other materials as well. Basically, any turning machine can be set up for rotary broaching after an inexpensive tooling setup. After this initial investment and setup, further maintenance costs are low, especially in relation to how quickly and inexpensively parts may be completed.
Choosing the Proper Rotary Broaching Supplier
To make sure you have the most beneficial outcome when purchasing Rotary Broaching from a Rotary Broaching Company, it is important to compare at least 4 or 5 Companies using our list of Rotary Broaching suppliers. Each Rotary Broaching Company has a business profile page that highlights their areas of experience and capabilities and a contact form to directly communicate with the manufacturer for more information or request a quote. Review each Rotary Broaching company website using our proprietary website previewer to get an idea of what each business specializes in, and then use our simple RFQ form to contact multiple Rotary Broaching businesses with the same quote.
Rotary Broaching Informational Video
Broaching Power Pages
Broaching is a machining process where a sharp, hardened, toothed tool removes material from a workpiece in a consistent, continuous, and accurate way. The process of broaching uses a tool with raised teeth of differing sizes that...
5 Axis CNC Machining
The normal functioning of CNC machines is done along the three Z, X, and Y axes. The five axes machines have two more axes accessible, which are namely A and B. The addition of the two extra axes makes it easy to cut complex and intricate parts...
CNC machining is an electromechanical process that manipulates tools around three to five axes, with high precision and accuracy, cutting away excess material to produce parts and components. The initial designs to be machined by CNC machining are created in CAD...
Precision sheet metal fabrication is a common manufacturing process where the structure of a metal workpiece is cut, bent, and assembled by machining. There are any number of operations that are performed in the creation of a finished sheet metal product...
Sheet Metal Fabrication
Sheet metal fabrication is metal that has been formed into thin and flat sheets which is then cut and bent into various shapes. Different metals, brass, steel, copper, tin, titanium, aluminium, etc., can be made into sheet metal...
Thread rolling is a type of threading process which involves deforming a metal stock by rolling it through dies. This process forms external threads along the surface of the metal stock...