A

lthough its not one of the most common machining operations, broaching has been around the metal working industry for well over a century. The processone of the quickest and most precise metal removal methods availablehas come a long way since the first broach drift was hammered through cast iron well over 100 years ago. Curiously enough, the evolution of the broaching process has nearly brought it back full circle, to the first belt-driven flywheel machines developed early in the 20th century. The earliest incarnation of the broaching process utilized incrementally sized drifts that were hammered through the bores of parts one at a time. Numerous drifts of different sizes we required to finish a bore to the required size. The process, of course, was slow and extremely labor intensive. The first milestone in the evolution of the broaching process was the introduction of the first broaching machines, which were simple beasts with very few moving parts. The principle was simple: attach a belt to a flywheel, turn the flywheel, which turns a gear, which then transfers rotational energy to a screw or rack. The turning of the screw, or moving of the rack, would then move a slide, which would draw the cutting tool through the workpiece. The accuracy, repeatability, and precision of parts cut on this type of screw-driven broaching machine was excellent, but the process was slow. The next step in the evolution of the broaching process saw hydraulic powered machines replacing the old screwdrive machines.

New hydraulic-powered machines replaced the old screw-drive variety

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By Matt Egrin

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new broaching processes were invented, the machine was Hydraulically driven machines yielded faster cycle times, still very much the same as ever; a glorified log-splitter. and the increased cutting forces that hydraulic power was The inception of cell type manufacturing and tougher enviable to achieve allowed many new operations to be performed by broaching that could not be done prior to the ronmental preservation standards were the catalysts in the next evolution of broaching inception of the hydrauliequipment. Traditionally, a cally powered machines. machine possessing more Broaching grew from than 36 of cutting stroke strictly an internal machining process, creatnecessitated either a pit mount or an operator stand. ing such features as splines Machines mounted in pits and keyways, to a machinwere closer to groundwater. ing process that was able If any fluids leaked out of to duplicate many milling the machine, or were spilled operations in a fraction of during the filling or draining the cycle time, and often process, there was a danger with better part finishes of groundwater contaminaand tolerances. tion. On the other hand, a The floodgate was floor-mounted machine, opened. Operations never which required the operator before done on a broach to operate the machine from were now being processed New machines expanded production capacity a platform, was unacceptmore quickly and with betable in the new manufacturter tolerances by using the ing cells, where a single operator was expected to run mulnew, hydraulically powered machines. tiple machinesunless the operator happened to wear a cape The broaching process continued along in much the same and a blue spandex suit with an S on it, climbing up and way for decades. While new technologies were adopted in down stairs all day was not an option. This was the rebirth of electrical controls, hydraulic systems were developed, and

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Pit-mounted machine

Cell-Mate table-up machine

the table-up broaching machine, and I say rebirth because the technology was developed in the early 1950s but abandoned. In the case of Broaching Machine Specialties, an automotive manufacturer in Oregon was instructed to get their machines out of the pits because contamination was already evident. This requirement led to the development of our first Cell-Mate table-up machine in 1993. Since then

BMS has shipped over 40 of these machines to manufacturers throughout the world. The table-up machines operated differently than the traditional pull-down version. Instead of the workpiece being held stationary above the floor and the tool moving down through it, the table-up design holds the cutting tool stationary and moves the part up over the stationary tool. This allows the part to be loaded at floor level and eliminates the need for a pit or operator stand; no groundwater problems, and no need for a flying operator. Cost cutting and tighter surface finish requirements drove the next evolution of the broaching process. Hydraulically powered machines utilize an electric motor to power the hydraulic system. This motor runs constantly even if the machine is in a static condition, such as between cycles or

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idling. The constant running of the motor uses valuable electricity and wastes a considerable amount of money in the course of a year. Broaching machine manufacturers answered the call to save energy by implementing the use of electromechanically driven machines. The hydraulic cylinder was replaced by a planetary roller-screw and a motor that runs only on demand, such as during the cutting or return stroke, replacing the constantly idling motor. Furthermore, the constant torque of a mechanically driven system yields better surface finishes than are achievable from hydraulically driven machines. This is due to the compressibility of hydraulic oil. High-speed photography of a hydraulically powered broaching machine filmed during the cutting stroke will show the slide and cutting tools pulsating or chattering through the cut. An electromechanical machine with its roller-screw drive has no compressibility and moves at a constant speed with a constant torque. It is the smooth, nonpulsating cutting action that yields a far better surface finish. In the case of BMS, an air brake manufacturer whose surface finish requirements were extremely rigorous led to the development of our first Electro-Mate screwdriven, electromechanically powered table-up broaching machine. Other advantages afforded by the electromechanical drive machines are: Because no hydraulic unit is required, the machine takes up 50 percent less floor space. This can be a major factor when designing a machining cell (see picture on page 33). No pumps, valves, hydraulic leaks, or maintenance. No need to stock hundreds of gallons of hydraulic oil. No need to filter or dispose of spent hydraulic oil. Smooth cutting action yields better tool life and part finish.

Electromechanical drive

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CURIOUSLY ENOUGH, THE EVOLUTION OF THE BROACHING PROCESS HAS NEARLY BROUGHT IT BACK FULL CIRCLE, TO THE FIRST BELT-DRIVEN FLYWHEEL MACHINES DEVELOPED EARLY IN THE 20TH CENTURY.
Because no excess heat is generated by a constantly idling motor, a cooler working environment results. So here we are, having come nearly full circle. The newest technology in broaching, screw-driven broaching machines, is a new twist on an old technology. Use any clich you see fit, whether that be Old habits are hard to break or Keep it simple, stupid. But the one I prefer is What goes around, comes around.
ABOUT THE AUTHOR: Matt Egrin is vice president of Broaching Machine Specialties Company of Novi, Michigan. The company specializes in turnkey broaching systems, including eight standard lines of broaching equipment, special machines for unique applications, remanufactured and used broaching machines and sharpeners, broaching machine parts and service, broach cutting tools, and design and contract broaching services. Egrin can be reached at (800) 229-4666 or bms@broachingmachine.com. The companys Web site is [www.broachingmachine.com].

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