Keys to Using CNC Broach Tools

General Speeds/Feeds/Set-up

Speeds – 200 to 550 IPM (Inches per Minute)

Feeds – .0008″ – .0015″ DOC (Depth of Cut per pass)

Examples:

  1. In 4140 – .0008″ DOC at 225 IPM
  2. In Aluminum – .0015″ DOC at 450-550 IPM
  3. In 8620 – .001″ DOC at 250 IPM

Programming

  • Program the tool to drop completely out of the keyway on the retraction, you do not want to drag the nose of the insert back through the slot on the retraction
  • Start cut with approx. 1” of space between the face of the insert and the part to allow space to accelerate to full cutting speed
  • imageFailure to have adequate “acceleration space” could result in deflection or tapering

Set-up

How rigidly you hold our tool is the difference between whether it works well or not-

  • Use an ER collet or Cat40 style holder that holds the tool with multiple points of contact from different angles, we do NOT recommend you hold your ER collet shank in a VDI boring bar sleeve
  • End mill holders, boring bar sleeves or solid tool holders with only 2 screws from one direction are not adequate for best insert life
  • Take the time to indicate in your “Squareness to the Part at the Tip of the Cut” with gauge blocks
  • Our tools are long. If the tool is off in your holder by a .0001”, when you Trig out the length of the tool, 5” out at the tip of the cut you will be hitting the part “off”, dramatically decreasing your insert life

imageimage

For the Operator

  • Do not over-tighten the set screws on our broach tools. Just snug them up.
  • Change the insert cutting edge out. A worn out insert will have a rounded, dull edge and won´t cut the part, but rather deflect. The force has to go somewhere.
  • Ensure the part you are cutting is clamped rigidly enough to withstand getting hit.
  • Use water soluble coolant with a 12-15% oil content from optimum insert life.

TESTIMONIALS

"We recently ran up against a tough lot of Monel sockets requiring slotting six places through a helix. The material was far harder than usual, and our usual rotary broach couldn't handle it. Because the run was short, we couldn't spend a lot on tooling. The CNC Broach Tool Company tool cut the nasty stuff beautifully, even through the interrupts, and got the job done with less burring and deformation. Even managed to salvage the part that the old broach broke down on. Good job! Thanks for the help."

Karl Mech Hydrasearch Co, Stevensville, MD

"We currently implemented a broach tool from CNC Broach Tool Company, it was a broach application that was not a through hole which required us to look into farming out this application. With implementing the CNC Broach Tool Company tool we were able to not only keep this operation in house, we were able to combine it to the lathe operation and also because of that we were able to add the drill and tap cross holes to make it complete in one operation which is always a cost savings if you don't have to handle the parts more than once. Centerline held real well because the bore and the broached keyway were done in the same operation."

Monty Twingstrom CNC Manager, K-Manufacturing, Inc., Osseo, MN

ID Broaching a Blind Hole in 304 Stainless

Mike Turner, operations manager at Derby Machine (Derby, Kansas) had a problem: Finding a vendor that could ID broach a blind hole in 304 stainless steel to proper size/accuracy specifications forced the company to ship its parts from Kansas to Chicago at $15 per part with a $100 setup fee, plus shipping both ways.

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ID Broaching a Blind Hole in 304 Stainless

Mike Turner, operations manager at Derby Machine (Derby, Kansas) had a problem: Finding a vendor that could ID broach a blind hole in 304 stainless steel to proper size/accuracy specifications forced the company to ship its parts from Kansas to Chicago at $15 per part with a $100 setup fee, plus shipping both ways.

READ MORE