About Rotary Broaching
Knowledge

About Rotary Broaching

Rotary broaches (also known as oscillating or hexagonal broaches) are one of the commonly used CNC tools in metal-cutting production. It is used to process polygonal parts and inner holes (especially suitable for blind holes) and other special-shaped inner holes.
Published: Apr 12, 2023
About Rotary Broaching

What is Rotary Broaching?

Rotary tool holders can be used on any CNC machine tool and Swiss slitting lathe (core walking machine) to process hexagonal screws or other lathes. The rotary broach tool holder has an internal movable spindle for clamping polygonal tools.

In CNC lathes or other lathes, the rotating tool holder is fixed on the machine tool holder. The movable spindle and rotating broach rotate together with the work piece. Driven by the work piece, the corners of the rotating cutter constantly change the contact points on the work piece and perform a swinging action when cutting every corner of the shape. In a CNC milling machine, the main body of the tool holder rotates together with the machine tool spindle, while the inner spindle and rotating tool of the rotary broach remain stationary. This also produces a swinging motion, and the cutting edge of the rotating tool continuously changes the contact point on the work piece. To produce the required polygon products.

The rotary broach manufactured through a proprietary hardening process can cut materials with a hardness of up to 50 HRC with minimal tool wear, thereby improving the production process of medical screws and other components.

Rotary broaches need to be ground to suit each specific application because the shape of the cutting tool needs to reflect the required hole geometry. Their design is offset by 1 degree along the longitudinal axis, thus creating a "swing" that allows the cutter to cut hexagonal and square holes.

High-volume CNC machining environments often rely on small process improvements to save a lot of money for a given job. Economies of scale simply mean that reducing the processing time of a cycle by a few seconds will result in a reduction of the total time required to process all parts by several hours. But just like the money saved in a high-volume environment, the cost will increase. This is usually the main obstacle in the production of medical-grade screws.

Medical screws pose a challenge to manufacturers because manufacturers have to join the scale of high-volume work while also facing difficult materials. Using titanium and high-strength metals such as low-nickel alloys such as B-ioDur 108, medical screws usually require a strong cutting tool to perform any cutting, which can even damage the life of the tool. When the output is high, the annual increase in mold costs may surge to tens of thousands of dollars, or even more. For screws that require rotary broaching, the cost is particularly high.

High output, hard material
Rotary broaching, also known as oscillating or hexagonal broaching, is a machining process that uses cutting tools with shapes that match the desired hole geometry to place a square or hexagonal hole in the part. The longitudinal axis of the tool is offset by 1 degree from the axis of the work piece, which will cause "swing" when rotating. The swing causes the broach to cut into the side of the guide hole when driven into the work piece, thereby forming the required square hole and hexagonal hole.

Structure of Rotary Broach

  • The tool body, this part is used to connect the key parts of the processing equipment (the conventional product is a straight shank cylinder). Such as: fixed on the CNC lathe tool holder. The milling machine uses a collect to hold the tool body. The commonly used clamping method of the CNC milling machine is to fix it with the cable nozzle of BT/NT/HSK series tool holder. In practical applications, the rotary broach body also involves Morse shank, BT shank, NT shank, HSK shank, and other shape interfaces.
  • Internal movable spindle, this part is the core key assembly of the rotary broach. The internal active spindle structure is very copy and precise. Assembled by precision components such as camshafts, planetary gears, self-aligning ball bearings.
  • Polygonal cutter. The polygonal cutter is customized according to the shape to be processed. For example, hexagonal, square hole, octagonal, dodecagonal, zigzag, involute spline, straight spline, plum blossom, D-shaped hole and other shapes (special shapes are often encountered in practical applications).

The working method of rotary broach:
In CNC lathes or other lathes, the rotating tool holder is fixed on the machine tool holder. The movable spindle and rotating broach rotate together with the work piece. Driven by the work piece, the corners of the rotating tool continuously change the contact points on the workpiece, and swing-type cutting is performed when cutting every corner of the shape.
In a CNC milling machine, the main body of the tool holder rotates together with the machine tool spindle, while the inner spindle and rotating tool of the rotary broach remain stationary. This also produces a swinging motion, and the cutting edge of the rotating tool continuously changes the contact point on the work piece. To produce the required polygon products.

Material that can be cut by rotary broach:
(Non-ferrous metals) aluminum alloy, brass, red copper, etc., carbon steel, stainless steel, high-temperature alloy steel, plastic products, hardwood, etc.

Published by Apr 12, 2023 Source :mmsonline, Source :club.1688

Further reading

You might also be interested in ...

Headline
Knowledge
How Does the Electroplating Process Work for ABS Plastic?
Over the past few years, plastic electroplating has gained widespread popularity, particularly in the decorative electroplating of plastic components. Among the various types of plastic utilized in electroplating, ABS plastic stands out as the most extensively employed.
Headline
Knowledge
What Are the Fundamentals and Benefits of Choosing between Liquid and Powder Coating?
Metal fabricators aiming to venture into finishing processes should familiarize themselves with two prevalent options—liquid and powder coating—along with the prerequisites necessary for a company seeking to employ either or both.
Headline
Knowledge
Anticipating the Emerging Trends in the Global Laser Industry
In light of the evolving global industry demands, the laser industry and technology are shifting their focus towards meeting the requirements of 5G semiconductors and smart vehicle processes. While Taiwan's laser industry has a well-established foundation built over the years, sustaining international competitiveness necessitates a proactive advancement in independent laser technology.
Headline
Knowledge
What is the Purpose of Surface Treatment for Metals?
Defects are bound to arise during the reprocessing of mechanical equipment or parts related to metal. As a result, the final item's surface treatment process plays a crucial role, serving the dual purpose of enhancing aesthetics and providing protection. This process not only improves the performance of metal parts but also helps prevent rust.
Headline
Knowledge
Selecting a Hydraulic Press and Understanding its Manufacturing Procedure
Hydraulic presses find applications in compaction, assembly, pressing, forming, embossing, and stretching. They play a crucial role in compaction within the cosmetics sector, assembly in the automotive industry, molding of electronic products, and stamping in the home appliance industry.
Headline
Knowledge
Introduction to RFID Tags: The Significance of RFID in Modern Retail Supply Chains
There are two types of RFID systems: passive and active. For those unfamiliar with RFID, you may be curious about the distinctions between these types and which one suits your application best. In the following, we offer a brief explanation.
Headline
Knowledge
Anticipating the Emerging Trends in the Global Laser Industry
In light of the evolving global industrial demands, the laser industry and technology are shifting towards meeting the requirements of 5G semiconductors and advanced processes for smart vehicles. While Taiwan's laser industry has made substantial progress over the years, maintaining alignment with international advancements necessitates a proactive push in independent laser technology.
Headline
Knowledge
Exploring Sheet Metal: Defining Sheet Metal and its Various Applications, with a Focus on Laser Applications
The term originates from English, known as plate metal. Typically, certain metal sheets undergo plastic deformation either manually or through die-stamping to attain the desired shape and size. These sheets can then undergo additional shaping through welding or a limited amount of mechanical processing to create more intricate components.
Headline
Knowledge
Comprehending CNC Motion Control and Three Common Types
The primary advantage provided by various types of CNC machine tools is enhanced automation, as it allows for the reduction or elimination of operator intervention in the production of workpieces.
Headline
Knowledge
How is Automatic Optical Inspection (AOI) Technology involved?
What is AOI? AOI stands for automatic optical inspection technology, known for its non-contact nature, rapid speed, high precision, and stability. This technology effectively addresses the limitations of manual visual inspection in quality management.
Headline
Knowledge
What Constitutes a Planing Machine?
A shaper is a machine tool that employs the relative linear motion between a workpiece and a single-point cutting tool to shape a linear toolpath. Its cutting process is similar to that of a lathe, but it typically follows a linear, as opposed to a helical, trajectory.
Headline
Knowledge
What Constitutes the Principal Components of a Shaper Machine?
Shaper machines are intricate pieces of equipment designed for precision machining. They comprise several essential components, each contributing to the machine's overall functionality and effectiveness. To gain a comprehensive understanding of how a shaper machine operates, it's crucial to examine the role and interplay of these individual parts within the complete system.
Agree