American Broach Tools

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Broach Cutting Tools

Internal & Pot Broaches

Round Broaches
	Round broaches are used to finish holes in parts where close tolerances and good surface finishes are required. They are either pulled or pushed through the work pieces. Round broaches usually have roughing semi-finishing and finishing teeth. Each tooth increases in diameter up to the finishing teeth which all have the same diameter.
Spline Broaches
Cutting of splines in previously produced holes is one of the most widely used broaching applications. The splines are generated by the top of the tooth. Straight splines involutes or serrations can be produced by this method.
Helical Spline Broaches
	Broaching is the most economical method for cutting spiral transmission gears gun rifling and similar parts. The cutting teeth of the broach are ground with the desired form and helix angle. The broach can be rotated as it is pulled through the work piece or the broach can be restrained from turning and the part rotated.
Spiral Broaches
An excellent way to broach very short parts is with continuous engagements (spiral) broaches. The small length of cut precludes getting multiple teeth cutting at the same time with conventional broaches. The spiral prevents the part from dropping into the gullet causing damage to the broach tool and the workpiece. Spiral broaches yield less vibration better finishes and longer tool life when compared to conventional broaches.
Helical Spiral Broaches
	Using spiral teeth on a helical broach results in better part finish longer tool life and less vibration. Because the helical angle is 90 degrees to the spiral angle the chip does not snow plow against the side of the spline destroying the finish. The spiral teeth require a special sharpening machine.
Combination Broaches
Combination broaches are used where two or more matching operations are required and production requirements are high. Some teeth finish the hole while other teeth cut the splines. All spline broaches can be designed with alternating round and spline finish teeth to provide better concentricity between the minor diameter and the splines. Another popular combination is round and keyway (one spline) where the hole is finished and a keyway is also cut.
Form Pull Broaches
	In form broaching the broach starts in a round hole and finishes to an irregular shape. The most common broaches of this type produce oval square or hexagon holes. Any shape that can be developed from a round hole can be form broached.
Shell Broaches
Sometimes the tool life is very low in the finish section compared to the roughing teeth. Therefore it may be more economical to manufacture the finish section separate from the roughing section. The finish section would be called a shell and the roughing section the body. These broaches may be simple round tools or complex helical spiral assemblies.
Pot Broaches
	Cutting splines or forms on the outside diameter of a part is called pot broaching. The broach tools are mounted on the inside surface of a hollow housing (pot). The broach tools are either rings inserts or a combination of both.
Blind Broaches
Broach tools that cannot go through the inside of the part or over the outside of the workpiece because of an obstruction are called a blind broachs. A series of single teeth broach tools each progressively larger will develop the final form.
Keyway Broaches
	The slot on the inside bore of a workpiece is called a keyway. The keyway can be broached in a part very quickly. The keyway broach may be a rectangular bar guided by a workhorn. It may be a single spline internal broach or it may be an arbor with the broach screwed into a slot.
Bearing Cage Broaches
These tools typically broach two holes at the same time through opposite sides of a ring or bearing cage. The broached surfaces may be two opposite sides of the same hole or a square or rectangle with radii corners or barrel type rectangle holes. Guides groves are used to maintain centrality.

Surface Broach Cutting Tools (on Holder)

Surface Broaches
Surface broaches may be used to machine the exterior of a part . The surface broaches are mounted in a holder to properly locate the tools. The broach tools are typically small (4 to 20 inches long) so they can be manufactured and maintained easily.
Form Surface Broaches
	Form surface broaches can be used to machine a curve to the exterior of a part. These surfaces may be a very simple radius or a complex turbine blade form.