LECTURE NOTES

ON

“PRODUCT DESIGN AND PRODUCTION TOOLING”

Prof. Sushanta Kumar Pradhan

DEPARTMENT OF MECHANICAL ENGINEERING

RADHAKRISHNA INSTITUTE OF TECHNOLOGY AND ENGINEERING,

BHUBANESWAR- 752057 (ODISHA)
 SYLLABUS

PRODUCT DESIGN AND PRODUCTION TOOLING

SUBJECT CODE-PME6J001

MODULE – I (14 HOURS)

Product Design-Product design considerations, product planning, product development, value

analysis, product specification. Role of computer in product design. Process Planning – selection
of processes, machines and tools. Design of sequence of operations, Time & cost estimation
MODULE – II (14 HOURS)

Forging design- allowances, die design for drop forging, design of flash and gutter, upset
forging die design. Sheet metal working- Design consideration for shearing, blanking piercing,
deep drawing operation, Die design for sheet metal operations, progressive and compound die,
strippers , stops, strip layout.

MODULE – III (16 HOURS)

Design of jigs and fixtures, principle of location and clamping, clamping methods, locating
methods, Drill Jig bushing, Indexing type drilling Jig. Design of single point cutting tool, broach
and form tool. Tooling design for turret lathe and automats. Design of limit gauges.

TEXT BOOKS :

1. Product Design & Manufacturing, A K Chitale, R C Gupta, Eastern Economy Edition, PHI.
2. Product Design & Development, Karl T Ulrich, Steven D Eppinger, Anita Goyal, Mc Graw
Hill.
3. A Textbook of Production Engineering, P.C. Sharma, S. Chand & Co
REFERENCE BOOKS:
1. Fundamentals of Tool Engineering design, S.K. Basu, S.N. Mukherjee, R. Mishra, Oxford &
IBH Publishing co.
2. Technology of Machine Tools, Krar, Gill, Smid, Tata Mc Graw Hill
3. Jigs & Fixture Design, Edwrd G Hoffman, Cengae Learning.
MODULE-I
MODULE-II
 SHEET METAL WORKING (PRESS TOOLS)

Introduction :
A press tool is an assembled part of punch die and some other accessories or parts with which we
can produce a particular shape and size sheet metal component in mass production.

Sheet :
Sheet is the thickness of metal foil which varies from 0.5 mm to 6 mm that sheet thickness when
becomes 8 mm and beyond 8 mm, the sheet will be called as plates.

Punch :
It is the male part of press tool, which insert into the die to perform a particular operation. It is
mounted on the lower end ram and slides etc.

Die :
It is the female member of press tool assembly which has an opening or cavity to receive the
punch. It is clamped on the bolster plates fitted on the table and remain stationary.

Note :
• The punches and dies are generally made out of high carbon high chromium steel.
• Sometimes it may be made with cemented carbide.

Advantages of Press Tool :

➢ Mass production of the same component.
➢ No need to check all components.
➢ Rejection is less
➢ Less wastage of raw material.
➢ Less time taken.
➢ Component cost is very less.
➢ Not required high skill
➢ Better inter changeability.

Disadvantages :
➢ Initial cost is high
➢ Maintenance cost is high.
Components of press tool :

Classification of press tool operation :

Stresses induced Operations

1. Shearing Shearing, Blanking, Piercing, Trimming

Shaving, Notching, Nibbling.

2. Tension Stretch Forming

3. Compression Coining, Sizing, Hobbing, Ioning
4. Tension & Compression Drawing, Spinning, Bending, Forming.
Cutting Operation :

1. Blanking :
➢ It is an operation of cutting of flat sheet of a desired shape. In this operation
entire periphery is cutout and the cutout portion is our requirement and the
remaining portion is wastage (scrap).
➢ In this operation clearance is provided on punch.

2. Piercing :
➢ It is an operation of making hole in the sheet, here the entire periphery is cut out
and the cut out portion is wastage.
➢ In this operation clearance is provided on die.
3. Notching :
➢ Notching is the operation in which a desired shape from the edge of the strip is cut
out. This operation cut only two or three sides not the entire periphery.
➢ It is also removes the waviness surface or wrinkled surface. It is also provide
smoother surface finish.
4. Shaving :
➢ It is a secondary operation in which a very small amount of material is removed
from the edge of blank and prepierced hole. It is used often to get close tolerance
and smoother surface finish.
➢ The excess material is removed as a chip similar to the metal cutting tool.

5. Perforating :
➢ The perforation is an operation of producing no of holes in a certain pattern in the
sheet in a single stroke.

6. Cutting Off :
➢ Cutting off is an operation which separate the sheet in a straight line or cured line.
No scrap is produced in this operation.
7. Parting Off :
➢ It is an operation which the sheet along to straight or curved line or any profile.
The material removed by punch is separated.

8. Trimming :
➢ Trimming is an operation which removes the distorted, wavy, irregular, and
excess material from drawn sheet and forged part or tube upto a defined length or
portion.
9. Bending :
➢ It is an operation in which the bend takes place at an angle along the straight axis
and this is called as bend axis

10. Curling :
➢ It is an operation of forming the edge of a component into a roll a curl by bending
the sheet in order to provide strength and rigidity (remove the sharp edges).

11. Plunging (Hole Plunging) :

➢ It is the secondary operation of forming the flange in a prepierced hole for
accommodating a screw through the plunged hole. This operation is carried out
after the piercing.

12. Bulging :
➢ It is an internal forming operation used to extend the diameter of a shell.
13.Swaging (Necking) :
➢ This is the reverse of the bulging operation. In this operation the diameter of a
shell or tube is reduced upto a defined length or portion.
14. Ironing :
➢ It is a process of making uniform wall thickness and smoothing in the wall of a
drawing product.
➢ This operation is carried out by forcing of a punch from the inside of the drawing
product and it has the calculated interference. This operation also removed the
wrinkle surface.

15. Embossing :
➢ It is the operation in which the letter, ambulum and logos are projected.In yhis
operation the sheet thickness does not vary through out the component.
16. Coining :
➢ It is the squeezing operation.
➢ In this operation operation letters, logos and emblem on the both side of the sheet.
In this operation the sheet varies according to logos and emblem.

17. Drawing :
➢ It is the forming operation.
➢ In this operation sever plastic deformation takes place. This operation used to
make the cup and shell.
➢ Drawing is of two type –
➢ Shallow drawing (d/h)>2
➢ Deep drawing (d/h)<2
 Where
d- Mean dia of cup
h- Height of cup

18. Lancing :
➢ It is combination of cutting and bending operation. Here bending is done in a
straight line.
➢ No material edge cut free during lancing operation . The punch is so design to cut
metal from two or three side and bend along fourth side.
Ex- Mosquito coil stand
19. Lovering :
➢ Lovering is the operation in which cutting and forming takes place, No material
edge cut free in this operation.
➢ The punch is designed to cut the material in one straight line and forming all other
ex-window of train, it is the opposite of lancing.
➢ It is also performed on the cashing of electric panel or voltage stabiliser for better
heat transfer.

Types of Dies :
This dies may be classified according to the type of press operation and according to the method
of operation.
I. Type of press operation. According to this criterion, the dies may be classified as
: cutting dies and forming dies.
Cutting dies. These dies are used to cut the metal. They utilize the cutting or shearing
action. The common cutting dies are : blanking dies, piercing dies, notching, trimming,
shaving etc.
 Forming dies. These dies change the appearance of the blank without removing any
stock. These dies include bending dies, drawing dies squeezing dies etc.
II. Method of operation. According to this criterion, the dies may be classified as :
simple dies, compound dies, combination dies, progressive dies, transfer dies and
multiple dies.
Simple dies : Simple dies or single action dies perform single operation for each stroke
of the press slide.
Compound dies : In these dies, two or more operation may be performed at one
station. Such dies are considered as cutting tool since, only cutting operation are
carried out. The below Fig. shows a simple compound die in which a washer is made
by one stroke of press. The washer is produced by simultaneous blanking and piercing
operation . Compound dies are more accurate and economical in mass production as
compared to single operation dies.

Combination dies : In this die also more than one operation may be performed at one
station. It differs from compound die in that in this die, a cutting operation is combined
with a bending or drawing operation.
Progressive dies : A progressive or follow on die has a series of stations. At each
station an operation is performed on a workpiece during a stroke of the press. Between
stroke the piece in the metal strap is transferred to the next station. A finished
workpiece is made at each stroke of the press.
Strippers :
➢ The strippers remove the stock from the punch after piercing or blanking operation.
➢ On the return stroke of the punch , the scrap strip has the tendency to adhere to the punch
and be lifted by it.
➢ The action interferes the feeding of the stock through the die and some device must be
used to strip the scrap melt from the places as it clears up the die block such a device is
called stripper or stripper plate.
Types
I. Fixed strippers :- This stripper is attached at a fixed height over the die block .
This height should be sufficient to permit the sheet metal to feed freely be in
upper die surface and the sundered surface of the stripper plate.
II. Spring loaded stripper:- This is used in large blanking operation and also on
very thin and highly ductile material.
III. Hook pin stripper:- It can be considered as special case of fixed stripper
which is used to minimize the cost during low production die manufacturing.
Stop :
➢ Stops are essentially used for striping the block while feeding.
➢ After each blanking the strips has to be advanced a correct distance.
➢ The device used to achieve (position of the stock) is called stock stop.
Types of stop :
There are different type of stops are available according to requirement these
are –
I. Solid stop or shoulder stop
 II. Automobile stop
III. Pins top
IV. Latch stops
V. Starting stops

Strip layout :
➢ In the design of blanking die set, the first step is to prepare blanking layout that is to
layout the position of the workpieces in the strip and their orientation w.r.t one another.
This is called strip layout
➢ The factors which will influence the stock layout are –
I. Economy of material
II. Direction of material grain or fibre
III. Strip or coiled stock
IV. Direction of burr
V. Pressed used
VI. Production required
VII. Die cost
Shear :
MODULE-III
Design of Jigs and Fixtures

A jig may be defined as a device which holds and positions the work, locates or,

guides the cutting tool relative to the work piece and usually is not fixed to the

machine table. It is usually lighter in construction.

Jigs are used on drilling, reaming, tapping and counter boring operations.

A fixture is a work holding device which only holds and positions the work but

does not in itself guide locate or, position the cutting tool. The setting of the tool is

done by machine adjustment and a setting block or, by using slip gauges. A fixture

is bolted or, clamped to the machine table. It is usually heavy in construction.

Fixtures are used in connection with turning, milling, grinding, shapping, planning

and boring operations.

To fulfil their basic functions, both jigs and fixtures should possess the following

components or, elements:

1. A sufficiently rigid body (plate, box or frame structure) into which the

workpieces are loaded.

2. Locating elements.

3. Clemping elements.

4. Tool guiding elements (for jigs) or, tool setting elements (for fixtures).

5. Elements for positioning or, fastening the jig or, fixture on the machine on

which it is used.
Jigs and Fixtures are used –

1. To reduce the cost of production, as their use eliminates the layingout of work

and setting up of tools.

2. To increase the production.

3. To assure high accuracy of the parts.

4. To provide for interchangeability.

5. To enable heavy and complex shaped parts to be machined by being held

rigidly to a machine.

6. Reduced quality control expenses.

7. Increased versatility of machine tool.

8. Less skilled labour

9. Saving labour.

10.Their use partically automates the m/c torl.

11.Their use improves the safety at work, thereby lowering the rate of

accidents.

Locating and Clamping –

The overall accuracy is dependnt primarily on the accuracy with which the

workpiece is consistently located within the jig on fixture. There must be no

movement of the work during maching.

Locating refers to the establishment of a proper relationship between the workpiece

and the jig or fixture.

Clamping is to exert a force to press the workpiece agadust the locating surfaces

and hold it there against the action of cutting forces.

Figures

In a state of freedom, it may move in either of the two opposed directions along

three mutually perpendicular axes, xx, yy and zz. There six movements are called

“movements of translation”.

Also, the workpiece can rotate in either of two opposed directions around each

axis, clockwise and anticlockwise. These six movements are called “rotational

movements”.

The sum of these two types of movements, gives the twelve degrees of freedom of

a workpiece inspace. To confine the workpiece accurately and positively in another

fixed body (jig or, fixture). The movements, of the workpiece in any of the twelve

degrees of freedom must be restricted.

(a) The workpiece is resting on three pins A, B and C which are inserted in the

base of the fixed body.

The workpiece cannot rotate about the axes XX and YY and also it cannot move

downward. This wayt, the five degree of freedom 1,2,3,4, & 5 have been arrested.
(b) Two more pins D and E are inserted in the fixed body, ina plane perpendicular

to the plane containing the pins A,B and C. Now the workpiece cannot rotate about

the Z – axis and also it cannot move towards the left. Hence, the addition of pins D

& E restrict three more degrees of freedom, namely 6, 7 and 8.

(c) Another pin F in the second vertical face of the fixed body, arrests degree of

freedom 9.

Thus, six locating pins, three in the base of the fixed body, two in a vertical plane

and one in another vertical plane, the three planes being perpendicular to one

another, restrict nine degrees of freedom. Three degrees of freedom, namely, 10,

11, 12 are still free. To restrict these, three move pins are needed. Buyt this will

completely enclose the work piece making its loading and unloading into the jig or

fixture impossible.

Hence, these remaining three (10, 11, 12) degrees of freedom may be arrested by

means of a clamping device.

This method of locating a work piece in a jig or a fixture is called the “3-2-1”

principle or “Six point location” principle.

Locating devices –

Pins of various designs and made of hardened steel are the most common locating

devices used to locate a work piece in a jig or, fixture. The shank of the pin is press

fitted or, driven into the body of the jig or, fixture. The locating diameter of the pin
is made larger than the shank to prevent it from being forced into the jig or, fixture

body due to the weight of the work piece or, the cutting forces. Depending upon

the mutual relationship between the work piece and pin, the pins may be classified

as:

1. Locating pins 2. Support pins 3. Jack pins.

Principles for location purposes –

1. At least one datum or, reference surface should be established at the first

opportunity, from which subsequent machining will be measured.

2. For ease of cleaning, locating, surfaces should be as small as possible consistent

with adequate wearing qualities. Also, the location must be done from the

machined surface.

3. The locating surfaces should not hold swarf and thereby misalign the workpiece.

For this, proper relief should be provided where burr or, swarf will get collected.

4. Locating surfaces should be raised above surrounding surfaces of the jig or,

fixture, so that chips fall or, can be swept off readily.

5. Sharp corners in the locating surfaces must be avoided.

6. Adjustable type of locators should be used for the location on rough surfaces.

7. Locating pins should be easily accessible and visible to the operator.

Clamping –

If the work piece cannot be restrained by the locating elements, it becomes

necessary to clamp the work piece in jig or, fixture body. The purpose of clamping

is to exert a pressure to press a work piece against the locating surfaces and hold it

there in opposition to the cutting forces i.e, to secure a reliable (positive) contact of

the work with locating elements and prevent the work in the fixture from

displacement & vibration in machining.

Principles for Clamping Purposes –

Since the proper and adequate clamping of a work piece is very important, the

following design and operational factors should be taken care of

1. The clamping pressures applied against the work piece must counteract the tool

forces.

2. The clamping pressures should not be directed towards the cutting operation.

Whenever possible, it should be directed parallel to it.

3. The clamping pressure must only hold the workpiece and should never be great

enough so as to damage, deform or change any dimensions of the workpiece.

4. The clamping and cutting forces should be directed towards the locating pins;

otherwise the workpiece may get bent or forced away from the locating pins during

machining.

5. Clamping should be simple, quick and foolproof.

6. The movement of a clamp should be strictly limited.

7. Whenever possible, the lifting of the clamp by hand should be avoided if it can

be done by means of spring fitted to it.

8. Clamps should never be relied upon for holding the workpiece against the

cutting force. The cutting force should be arranged against a fixed stop or a

substantial part of the fixture body.

9. The clamps should always be arranged directly above the points supporting the

work, otherwise the distortion of the work can occur.

10. Fibre pads should be riveted to the clamp faces, oterhwise soft and fragile

workpiece can get damaged.

11. A clamp should be designed to deliver the required clamping force when

operated by the smallest force expected.

12. A clamp should be strong enough to with stand the reaction imposed upon it

when the largest expected operating force is applied.

13. Clamping pressure should be directed towards the points of support, otherwise

work will tend to rise from its support.

Clamping Devices – The commonly used clamping devices are –

1. Clamping screws 2. Hook blot clamp.

3. Lever type clamps 4. Quick acting clamps.

DESIGN PRINCIPLES COMMON TO JIGS & FIXTURES –

1. Since the total machining time for a work piece includes work handling time,

the methods of location and clamping should be such that the idle time is

minimum.

2. The design of jig and fixture should allow easy and quick loading and

unloading of the workpiece. This wil also help in reducing the idle tiem to

minimuse.

3. The Jig and fixture should be as open as possible to minimize chip or, burr

accumulation and tto enable the operator to remove the chips easily with a

brush or, an air jet.

4. The design features in the jig or fixture will be such that it becomes impossible

to load the work into the jig or fixture in an improper position.

5. Clearance – Clearance is provided in the jig or, fixture body for two main

reasons :

(i) To allow for any variation in component sizes, especially castings and

forgings.

(ii) To allow for hand, movements so that the workpiece can easily be placed

in the jig or, fixture and removed after maching.

6. Rigidity – Jigs and fixtures should be sufficiently stiff to secure the preset

accuracy of machining.

7. To simplify the handling of heavy jigs or, fixtures, the following means can be

adopted –

(i) Eye- bolts, lifting lugs can be provided for the lifting of the jig or, fixture.

(ii) If the workpiece is heavy, then the jig design should allow for side loading

and unloading by sliding the workpiece on the m/c table.

8. The use of ejection devices to force the workpiece out from the jig or, fixture.

9. Inserts – To avoid any damage to fragily and soft workpieces and also to the

fonishied surfaces of a workpiece clamping, inserts of some soft material such

as copper lead fibre, leather, hard rubber or plastic should be fitted to the faces

of the clamps.

10.Design for safety – Jigs/ fixtures must be safe and convenient in use. For that –

(i) Sharp corners on the body of the jig/fixture should be avoided.

 (ii) Bolts and nuts should be inside the body of the jig/fixture and protrude on

the suface.

11.Sighting Surfaces – Machining on a workpiece must be clearly visible to the

worker.

12.Simplicity in Design.

13.Economical.

14.They should be easy to set in the machine tool.

DRILLING JIGS –

Drilling jigs are used to machine holes in mechanical products. To obtain

positional accuracy of the holes, hardended drill bushes or, jog bushes are used to

locate and guide drills, reamers etc. in relation to the workpiece. The portin of the

jig into which the hardened bushes are fitted is called bush plate.

Drilling jigs are either clamped to the workpiece in which holes are to be drilled or,

the workpiece is housed and clamped in the jig body. If more than one hole is to be

drilled, the drill jig is made to slide on the table of the drilling machine.

Drilling jigs make feasible the drilling of holes at higher speed, with greater

accuracy and with less skilled workers than is possible when the holes are laid out

and drilled by hand.

Design Principles –
1. A drilling jig should of light in construction consistent with adequate rigidity to

facilitate its handling because it has to be handed frequently during the operation.

2. A drilling jig which is not normally clamped to the machine table should be

provided with jour feet so that it will rock if it is not resting equeare on the

machine table and so warm the operator.

3. The stability of a drilling jig should be as good as possible since it is not usual to

clamp it to the machine table and to ensure this, the feet or, base of the jig should

extend well outside the holes to be drilled.

4. Drill bushing should be fitted in fixed portoon of the jig.

Drill Bushes –

Jig bushings eliminate the elastic spring back in machining and easily locate the

tool relative to the wor.

Drill bushings are classified as

(1) Press Fit bushings.

(ii) Renewable bushes.

(iii) Linear bushes.

(i) These bushings are used when little importance is put on accuracy or, finish.

These bushing are installed directly in the jig body and are used mainly for short

production runs out requiring bush replacement.

(ii) When the guide bushes require periodic replacement (due to the wear of the

inside dia. of the bush, in the case of continuous or, large batch production), the

replacement is simplified by using a renewable bush. These are of the flanged type

and are sloding fit into the liner bush, which is installed (press fitted in the jig

plate). The liner bush provides hardened wear resistant mating surface to the

renewable bush. The renewable bushes must be prevented from rotating or, lifting

with the drill.

(iii) Liner Bushings – also known as ‘master bushings’ are permanently fixed into

the jig body. These act as guides for renewable type bushings. These bushings can

be with or, without heads. A liner bush is always used in conjunction with a

renewable bush.

Design Principles for Drill Bushings –

1. To facilitate easy entry of drills, the entrances to drill bushes should be

extremely smooth and well chamfered or, rounded.

2. There should not be any sharp corners on the body of the bush

3. Loose or, screwed in solid bushes should not be used where accuracy is

important.

4. The effective length of the drill bushing should be sufficient to guide and

support the drill.

5. Adequate provisions must be made for the chips that are produced and for their

easy removal.

6. The hole of the drill bushing should be from 0.00025 to 0.0025cm larger than

the drill size.

Jig bushings can be used to drill from 10,000 to 15,000 holes.

Indexing jigs and Fixtures –

Indexing jigs and fixtures are used when holes or, slots are to be machined to some

specific relationship, in a workpiece.

Indexing Devices – Many indexing jigs and fixtures employ a simple indexing
plate for their operation. Suppose six holes are to be drilled in a flange. The flange
can be mounted on an index plate which has six equispaced slots. The workpiece is
revolved under the drill and each hole is drilled in turn. For this an index plunger is
used which fots by turn into each slot in the index plate. To index the workpiece,
the plunger is pulled out of the slot. The index place and thereby the workpiece is
rotated ---- the next slpt comes in line with the index plunger into which it gets
pushed due to spring action.
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 BROACHING
INTRODUCTION

Before understanding the process of broaching and the related machining tools it is required to
know the clear difference between single point and multipoint cutting tool. A single point cutting
tool normally consists of a single cutting point or an edge used for cutting. The example of single
point cutting tool is turning tool used for turning tool is generally has more than one cutting
points or cutting edges in action at a time. Example of multipoint cutting tool are milling cutter
or a broaching tool.

Broaching is one of the metal machining operations done by a multipoint cutting tool called
broaching tool or broach. The tool is made reciprocating linearly relative to the workpiece in the
direction of tool axis. The relative movement, necessary fixtures for workpiece and the broach
are provided by a machine tool called broaching machine. The broaching operation is depicted in
Figure 2.1. The broaching is a high productivity method as so many cutting edges work to
machine the workpiece at a time. The tool may be pulled or pushed through the surfaces to be
finished. Surfaces finished by broaching either internal or external. External broaching is
performed on the outside surface of the workpiece to create a pre-decided shape with
dimensional accuracy and high degree of surface finish. Internal broaching is done on the
internal surfaces of the workpieces. This way internal surfaces are brought to exact size with the
required surface finish. Examples of the different shapes produced by internal and external
broaching are shown in Figure
 BROACH

As we know that the broach is a broaching tool, it consists of a series of distinct cutting
edges called cutting teeth along its length. Feed is accomplished by the increased step between
any two successive teeth on the broach. The total material removed in a single pairs of the broach
is the cumulative result of all the teeth in the tool in action (it is not necessary that all the teeth
available in the broach in action at a time). The cutting speed of the broach is decided by the
linear travel of the tool with respect to the workpiece. The shape of the cut surface (machined
surface) is determined by the contour of the cutting edges on the broach. Generally broaches are
made of high speed steel (HSS). In some cases the broaches are made of cast iron and their
cutting edges are made of cemented carbide inserts. These inserts are fastened to the right place
by mechanical means or brazed. A typical broach is shown in Figure 2.3 along with its
nomenclature.

Nomenclature of broach if expressed with its numerical values, called specification of broach.
This nomenclature is explained below.

Pull End Pull end is made to attach the broach to the broaching machine through the puller
head.

Front Pilot This centres the broach in the hole to be finished just before start of processing.

Roughing Teeth These are the cutting edges which remove larger amount of stocks during
cutting. Larger amount removal generates poor quality of surface finish but makes the operation faster.
Finishing Teeth These are cutting edges removing smaller stocks of material. These are used for final
finishing of the surfaces and their accurate sizing.

Rear Pilot and Follower Rest This is a supporting device to the broach when it is likely to
complete its operation of broaching.

Land It is the width of flank face of the broach normally it is kept slightly inclined to give relief
angle to the flank face of broach.

Pitch It is the distance between two corresponding points on two successive teeth of a broach.
Normally pitch of finishing teeth of a broach is kept comparatively smaller than the rough cutting teeth.
Height of the Teeth Height of the roughing and finishing teeth gradually increases from the shank to the
finishing teeth. This increment is called the cut per tooth, it depends on the material being machined.
Normally the cut per tooth is taken from 0.01 or 0.2 mm for the finishing teeth and it may go up 0.2 mm
for the cutting teeth.

DIFFERENT TYPES OF BROACHES

A broach is normally made in one piece and it is called a solid broach. Different types of the broaches
are described below.

Progressive Cut Broaches These broaches have cutting edges, a part of which are of the same height
along the broach but have different widths. In progressive cut broaching, metal is removed in thick
layers by each tooth from only part of the work surface. The last tooth of a progressive cut broach
remove a very thin layer over the entire profile of the work surface as in ordinary cut broaching.

Rotor Cut Broaching Rotor cut broaches are used for removing large amount of material in holes in
forgings or castings where a primary cutting operation is not desired. Their teeth are staggered around
the periphery at different sections so as to shear the work and allow chip clearance. This is
recommended for making square holes from a round cost one.

Burnishing Broaches Burnishing broaches are used for making glazed and finished surface on a steel
workpiece. These are used for finish the hole too. Burnishing teeth are rounded and not cut but
compress and rub the surface of metal. The amount of stock is intentionally left for burnishing. Its
thickness should not be more than 0.025 m

BROACHING METHODS

On the basis of method of broaching the operation of broaching is classified as discussed below.

Pull Broaching Workpiece is clamped to the broaching machine in stationary position and the broach is
pulled through the work. Broaches are usually long and are held in a special head. Pull broaching is
mostly used for internal broaching.

Push Broaching Workpiece is held in the broaching machine in stationary position and broach is pushed
through the portion of workpiece to the machined. Normally push broaching is done by hand and arbor
presses (hydraulic press). This method is also recommended for internal broaching like for sizing and
finishing the holes, cavities, and key ways.

Surface Broaching Any one of two, either workpiece or the broach (tool) is kept moving and other is
kept stationary. The method is widely used as surface finishing operation. In case of surface broaching,
the broaching tool is specifically designed for the shape to be finished.

Continuous Broaching In continuous broaching the broach is held stationary in the broaching machine
and workpiece is moved continuously. The teeth of movement of the workpiece may be either straight,
horizontal or circular. This is generally used for broaching a large number of similar workpieces at a time.

BROACHING OPERATION

Broaching operations are used for processing of various internal and external surfaces. This is also
recommended for processing of round and irregular shaped holes ranging from 6 to 100 mm size which
may have flat or contoured surfaces. Some of the cavities and holes are directly machined by broaching
operations, the example is spline hole. Sometimes execution of broaching operation requires more than
one pairs. The teeth of a gear or spline may be broached altogether or one or a few at a time. Normal
indexing operation (see milling machine operation for details) is done for cutting teeth by broaching.
After completion of broaching of one tooth indexing action is performed and another tooth is broached
and this continues till all the teeth are broached.

FIXTURES USED IN BROACHING

Fixtures plays important role in broaching operation. Fixtures are used for providing an accurate pre-
decided movement to broach with proper clamping action. Accuracy and rigidity of fixture make the
operation of broaching repeatable and fit for mass production. Functions of broaching fixture are
summarized as given below :

(a) Fixture holds the workpiece accurately and rigidity and moves it to the exact cutting position.

(b) Guide the movement of the broach in pre-decided manner relative to the workpiece.

(c) Fixture is also responsible to give feed motion to workpiece after completion of the cut.

MERITS AND DEMERITS OF BROACHING OPERATION

Broaching is widely used for faster finishing operations in metal working so it is a fit case for mass
production. Merits and demerits of broaching operations are described below.

(a) It gives high rate of production so recommended for mass production.

(b) Production run time in case of broaching is very large as a broach has very long life. The whole
processing load is shared by so many teeth.

(c) Due to faster operation and longer tool life, it is relatively cheaper.
(d) Both rough cutting as well as finished cutting can be completed in a single pairs of tool.

(e) Little skill or employment of semi-skilled manpower is sufficient to perform broaching operation.

(f) Broaching provides accurate and excellent quality of surface finish. It is capable to maintain tolerance
of the order of  0.007 mm and surface finish CLA value upto 0.8

(g) It is also capable to process internal and external surface including intricate shaped cavities.

(h) Broaching makes the effective use of cutting fluids as it facilitates the flow of cutting fluid into the
cuts.

In addition to the above merits the operation of broaching has some demerits, which are described
below :

(a) Broach is a multipoint cutting tool having multi cutting edges. Preparation of cutting edges is a costly
affair. Its initial cost is quite high.

(b) There is a limitation of size of workpiece in case of broaching. Very large sized workpieces can not be
subjected to broaching operation.

(c) Broaching is not possible for the surfaces having obstructions.

(d) Application of broaching is restricted upto finishing and accurate sizing as it can remove only small
stocks of material. Removal of larger stocks is not possible in broaching operation.

(e) There is a urgent need of rigid clamping of workpiece in broaching operation to maintain its accuracy
and finish. Clamping devices require frequent maintenance and cost.

MATERIAL OF BROACH

Common broach material is 18-4-1 stainless steel. As its name indicates, it has 4% chromium, 1%
vanadium and 18% tungsten. This is corrosion and wear resistant steel. Carbide is also recommended for
broach making, these broaches are used for broaching brittle material like cast iron in automobile
industry. Inserted bit type and cemented carbide type broaches are also preferred to reduce the cost of
broaches.
 Turret Lathe and Automats
Lathe

Lathe is a machine, which removes the metal from a piece of work to the required shape & size

Automatic Lathe
A lathe in which the work piece is automatically fed and removed without use of an operator.
Cutting operations are automatically controlled by a sequencer of some form.

Turret Lathe
lathe which have multiple tools mounted on turret either attached to the tailstock or the cross-
slide, which allows for quick changes in tooling and cutting operations.