Broaching, Sawing and

Filing
Chapter 27

Broach

Broaching Process

Originally developed for producing

internal keyways.
Multi-tooth cutter, single pass operation
Used in production to finish holes,
splines, and flat surfaces.
Rapid operation, low cycle times.
(V 20 to 50 ft/min)
Excellent surface finish produced (32 to
125 micro-inches)
Excellent tolerance

Broach Construction

Long multitooth cutter with

progressively deeper teeth, rise
per tooth
Rise per tooth:

Surface: 0.003 to 0.006 inches/tooth

Internal: 0.001 to 0.0025 inches/tooth

Chips produced are held in tooth

gullet during process

Broach Construction

Materials:

Styles:

High Speed Steel

HSS with TiN coating
Tungsten Carbide teeth (mass prod.)
Solid
Shell
Sections (larger surface)

Shapes

Holes (round, square, hex, )

Keyways
Internal Splines and gears
Flat surfaces
Spiral splines, gun barrel rifling

Broaching Requirements

Two teeth contact surface

Part must be able to withstand
high forces (35 to 300 tons/in2)
Surface must be accessible
High tool cost

Broaching Machines

Presses
Vertical Pull Down
Vertical Pull Up

Production
36 to 72 stroke
5 to 30 tons

Broaching Machines
Vertical - Dual

Broaching Machines
Vertical Surface

Broaching Machines

Horizontal
Capacity: 3-20 tons
Cutting Speed: 5-40
FPM

Broaching Machines

Horizontal
Surface Broach

10 ton
120 screw drive
Operation: broach
jet engine turbine
wheel rotor slots

Broaching Machines

Continuous Chain Broach

Part: Diesel Engine Connecting Rod

25 ton
220 travel

Sawing

Three styles of blades

Hacksaw
Bandsaw
Circular or cold saw

Sawing

Blade Material

Hacksaw, HSS
Bandsaw (teeth electron beam welded to
steel back)

HSS teeth
HSS with TiN coating
Tungsten Carbide
Tungsten Carbide grit
Diamond grit

Cold Saw; HSS, Tungsten Carbide inserts

Saw Tooth Form

Regular, Standard,
Precision

Skip, Buttress

Claw, hook

Saw Tooth Set

Regular

Raker

Aluminum,plastics
wood

General Purpose
Cutting

Wave

Cutting thin material

Blade Construction

Width

Thickness

Determines radius of cut possible

1/16 to 2
0.025 to 0.105

Pitch

3 to 24 teeth per inch

Size of teeth
Gullet size
Number of teeth in contact with work

Machinery
Vertical Bandsaws

Machinery
Horizontal Bandsaws

Machinery
Dual Column

Machinery
Large Dual Column

Machinery

Cold Saw

HSS, Carbide Tipped Blades

Manual
Automatic
14 to 18 blade

Machinery

Power Hacksaw

Accelerated
return stroke of
saw bow
Cutting
capacities up to
18

Filing

Used to remove small amounts of

material
Shapes

Files

American Pattern
Needle Files
Die Sinkers Riffler Files

Types of Teeth

Single Cut

Double Cut

Two sets of teeth, 1st at 40

2nd set at 70 to 80

Vixen Cut

Rows of teeth at 65-85

Curved rows of teeth

Rasp

Each tooth is a spike, raised

out of the surface by a
punch

File Coarseness

American Pattern Files

Swiss Pattern Files

Smooth
Second Cut
Bastard
No. 00, 0, 1, 2, 3, 4 and 6

The degree of coarseness is

greater for longer files

Filing Machines
Die Filing

Filing Machines
Disk Filing

Filing Machines

Band Filing
Machine

Rotary Burrs