Rotary broaching is a metalworking technique that cuts shapes such as hexagons and squares both internally and externally. It can be done by hand or with specialized equipment, including CNC systems for mass production. Lubrication is required to reduce friction and prevent overheating. Soft metals are more appropriate for broaching, and outsourcing may be a cost-effective option.
Rotary broaching is a metalworking technique used to cut shapes such as hexagons and squares, both internally and externally. In this process, a technician mounts a cutting head into a tool holder and feeds it into a component such as a bolt to cut it. The tool holder rotates, allowing the cutting head to dig in and produce the desired shape. A large assortment of symmetrical shapes can be cut in various metals using this technique, which can work extremely quickly to allow for high volume part production.
This metalworking process is sometimes known as swing broaching. This refers to the fact that because the tool head is positioned at a slight angle, the work appears to wobble while cutting. The angle allows the cutting head to apply pressure to only a portion of the component being machined at any given time. This allows the rotary broaching equipment to cut each side of the shape individually for high accuracy and reliability.
Rotary broaching can be done by hand or with specialized equipment. Computer numerical control systems allow operators to program in environments for mass production of identical parts. The technician determines what needs to be cut and how many components need to be included, and sets up the fixture to cut bolts and other products on an assembly line. Computers can control every step of the rotary broaching process for fully automated production, with periodic quality checks to make sure the equipment is working properly.
Facilities may also use other broaching techniques. The best option depends on the workpieces and the type of metal involved. Softer metals tend to be more appropriate for broaching, as they are less likely to chip or plug the cutting head as it moves through the materials. Lubrication must be provided throughout the cutting process to reduce friction, prevent overheating, and trap chips and chips from escaping into the work area, where they could cause injury or damage equipment.
Costs for a rotary broaching system can depend on size and capacity. It may be possible to rent or lease the equipment if a metalworking facility does not wish to purchase it. Companies with limited broaching needs may outsource the job, as they may be able to do it more cost-effectively and with the utmost accuracy due to their extensive experience. This method allows for very precise screw heads, internal threads, and other cuts on metal workpieces.
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