Broaching guide, straight milling

Broaching is a mechanical finishing process widely used to achieve high standards of precision and surface quality on a wide range of mechanical parts. This process, which combines rotary and translator movements, is particularly effective in removing excess material and obtaining a smooth and precise surface.

Broaching can be performed on different types of materials, including metals, alloys, plastics, and even ceramics. Its versatility makes it an attractive option in various industrial sectors, such as automotive, aerospace, energy, medical engineering and many others.

How broaching works

The process involves the use of a tool called a broach, composed of a series of cutting blades positioned on a cylindrical body. During the broaching operation, the broach is rotated and advanced within the workpiece. The rotation of the tool allows the blades to cut and remove excess material, while the translational feed ensures uniformity.

One of the distinctive features of broaching is the possibility of obtaining complex shapes and dimensions, even in areas that are difficult to reach with other finishing processes. This is possible thanks to the specific shape of the broach blades, which can be customised according to the specific needs of the workpiece to be machined.

The advantages

Broaching offers numerous advantages over other finishing methods. First of all, it is able to obtain very precise tolerances, of the order of microns, guaranteeing excellent surface quality. Secondly, it greatly reduces the time required for finishing compared to other processes, such as manual abrasion. In addition, it is a highly automated process, which makes it suitable for large-scale production.

Areas of application

A common field of application for broaching is the automotive industry, especially for working engine cylinders, which require high precision to ensure efficient operation. In this case, broaching is used to finish the cylinders, improving their smoothness and reducing wear. Similarly, bearings and sealing surfaces can also be broached, in order to obtain precise tolerances and an optimal surface finish.

In the aerospace industry, broaching is used to work on critical components such as aircraft turbines. Turbine blades require careful finishing to ensure efficient airflow and reduce vibration. Broaching is able to meet these critical requirements and provide an excellent surface finish.

Another sector in which broaching is widely used is medical engineering. In the production of prostheses and orthopaedic implants, for example, it is essential to obtain a smooth and imperfection-free surface to ensure proper integration with biological tissues. Broaching allows you to achieve this required precision and quality.

Broaching also finds applications in the energy industry, such as in the production of turbines for wind power plants or generators. Precise and accurate finishing of internal components contributes to friction reduction and increased energy efficiency.

In general, broaching has undergone several technological improvements over the years. The use of CNC (Computer Numerical Control) machines has made the process even more precise and repeatable. In addition, abrasive jugs have been developed that allow you to work with harder and more resistant materials.

However, it should be noted that broaching requires specialised skills and specialised machinery. Therefore, operators must be trained to properly manage the equipment and control the process to ensure optimal results.

Conclusions

Broaching is a mechanical finishing process widely used in industry to obtain precision parts with high surface quality. Thanks to its versatility, it can be used in different sectors such as automotive, aerospace, medical engineering and energy. 

Broaching offers numerous advantages, including precise tolerances, an excellent surface finish and reduced processing times. 

Although the continuous development of technologies has simplified the processing process, broaching requires operators with highly specialised skills and the use of specialised machinery.