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Broaching
By S K
Reamin
g
Video
Reaming
Reaming removes a small amount of material from the
surface of holes.
It is done for two purposes: to bring holes to a more
exact size and to improve the finish of an existing hole.
Multiage cutting tools that has many flutes, which may
be straight or in a helix are used.
No special machines are built for reaming. The same
machine that was employed for drilling the hole can be
used for reaming by changing the cutting tool.
Only a minimum amount of materials should be left for
removal by reaming. As little as 0.1 mm is desirable, and
in no case should the amount exceed 0.4 mm.
A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
Reamer
Reamer Flutes
Types of Reamers
The principal types of reamers are:
1. Hand reamers
a. Straight
b. Taper
2. Machine or chucking reamers
a. Rose
b. Fluted
3. Shell reamers
4. Expansion reamers
5. Adjustable reamers
Vide
o
Reaming
To meet quality requirements, including both finish
Reaming
Reamers, like drills, should not be allowed to become dull.
Rose Reamer
Rose chucking reamers are ground
cylindrical and have no relief behind the
outer edges of the teeth. All cutting is done
on the beveled ends of the teeth
Chucking Reamer
Fluted chucking reamers have relief behind
the edges of the teeth as well as beveled
ends. They can cut on all portions of the
teeth. Their flutes are relatively short and
they are intended for light finishing cuts.
Shell Reamer
Shell reamers often are used for sizes over
20 mm to save cutting-tool material. The
shell, made of HSS for smaller sizes and
with carbide edges for larger sizes or for
mass-production work.
Trepanning
Trepanning Tool
IES - 1999
Which one of the following processes
results in the best accuracy of the hole
made?
(a) Drilling
(b) Reaming
(c) Broaching (d) Boring
IES - 1999
Consider
the
following
statements
regarding reaming process:
1. Reaming generally produces a hole larger
than its own diameter
2. Generally rake angles are not provided on
reamers.
3. Even numbers of teeth are preferred in
reamer design.
Which of these statements are correct?
(a) 1 and 2(b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
IES - 1993
A hole of 30 mm diameter is to be produced by
reaming. The minimum diameter permissible is
30.00 mm while the maximum diameter permissible
is 30.05 mm. In this regard, consider the following
statements about the reamer size:
1. The
2. The
mm.
3. The
mm.
4. The
mm.
Of these statements
(a) 1 and 4 are correct (b)
(c) 2 and 3 are correct (d)
IES - 1992
Shell reamers are mounted on
(a) Tool holders (b) Amour plates
(c) Arbor
(d) Shanks
Borin
g
Boring
Boring always involves the enlarging of an existing hole,
Vide
o
Boring
The same principles are used for boring as for
turning.
The tool should be set exactly at the same
height as the axis of rotation. Slightly larger end
clearance angles sometimes have to be used to
prevent the heel of the tool from rubbing on the
inner surface of the hole.
Boring
Because the tool overhang will be greater, feeds
Cutting Time,CT L A O
fN
MRR
D12 D22
4 / fN
Davg dfN
mm
Broachi
ng
Broaching
Broaching is a multiple-tooth cutting operation with the
tool reciprocating.
Since in broaching the machining operation is
completed in a single-stroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
corresponding to the feed per tooth of a milling cutter.
The shape of the broach determines the shape of the
machined part.
Broaching was originally developed for machining
internal keyways, but looking at the advantages, it has
been extensively used in the mass production of
automobile component manufacture for various other
surfaces as well.
Broaching
The material removal using the broach teeth is
Vide
o
Broach Construction
Broach Construction
The broach is composed of a series of teeth,
Broach Construction
The last set of teeth is called the finishing or sizing
Broach Construction
The rear pilot helps to keep the broach to
Broach Construction
Broaches are generally made of high speed
Broach Construction
For smooth operation, it is essential that at
Advantages of broaching
1. It is the fastest way of finishing an operation with a single
stroke.
2. Since all the machining parameters are built into the
broach, very little skill is required from the operator.
3. Broaching machine is simple since only a single
reciprocating motion is required for cutting.
4. Final cost of the machining operation is one of the lowest
for mass production.
5. Any type of surface, internal or external, can be generated
with broaching.
6. Many surfaces, which are very difficult or impossible by
other means, can be done by broaching. For example, square
hole and internal splines.
7. Good surface finish and fine dimensional tolerances can be
achieved by broaching, often better than boring or reaming
Limitations of broaching
1. Custom made broaches are very expensive and
can therefore be justified only for very large volume
production.
2. A broach has to be designed for a specific
application and can be used only for that application.
Hence, the lead time for manufacture is more for
custom designed broaches.
3. Broaching, being a very heavy metal removal
operation, requires that the workpiece is rigid and
capable of withstanding the large forces.
4. Broaching can only be carried out on the workpiece
whose geometry is such that there is no interference
for the broach movement for the cutting.
IES - 2007
Among the following machining processes,
which can be used for machining flat
surfaces?
1. Shaping 2. Milling 3. Broaching
Select the correct answer using the code given
below:
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3
Q. No
1
2
3
4
5
6
7
Option
A
D
A
B
C
B
D
Q. No
8
9
10
11
12
13
Option
D
A
B
C
C
B