Adjustable Broaching Head 3. Fixed Braoching Heads 4. Broaching Bits Hexagonal 5. Broaching Bits Square 6. Broaching Bits Torx 7

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1 Rotary Broaching Heads & Accessories The Broaching Toolholder is a device that enables the processing of regular shapes (hexagons, squares etc.) in through and blind holes. The Broaching Tool is inclined from the centreline, this enables the it to shear its way into the workpiece. The holder can be supplied with various back-ends (cylindrical, Morse taper and VDI) for applications on most types of machines (CNC lathes, Machining Centres etc.). Adjustable Broaching Head 3 Fixed Braoching Heads 4 Broaching Bits Hexagonal 5 Broaching Bits Square 6 Broaching Bits Torx 7 Broaching Bits External 7 Cutting Data 8

2 The Adjustable Broaching Head is designed to generate Hexagons, Squares and Torx* forms during the machining cycle. Series Reference d H L D F S Series Reference d H L D F S MT MT /4" D /8 D /4" / The adjustable Rotary Broaching Head has advantages over the fixed type 1). It can be reset allowing the Broaching Bits to be reground ) Can be adjusted to allow for misalignment between turret and workpiece Setting example: Assemble Broaching Bit & measure length X. Replace Broaching Bit with test bar & mark position X. Locate the tool in the machine or V Block and lightly clamp. Tape the rotating spindle to the head (so they can revolve as one). Set a Dial Gauge at position X and rotate the tool. Using screws Y & W adjust to 0.03mm TIR The centre-point K is now positioned on the centreline of the shank (d). If the turret clamping hole is not in line with the turret you can set it by countersinking (45 ) a test component (larger diameter than the Broaching Bit). Loosen the clamping screws (W & Y) and advance the tool into the countersink allowing it to centre itself. Then tighten the clamping screws (W & Y) being careful not to disturb the alignment. (Providing the machine is in good alignment and original equipment Broaching Bits are used this holder can be used from new without any adjustment) 3

3 Fixed Broaching Heads cylindrical shank Series Reference d I L D F H Series Reference d I L D F H MT 69 F / / F /4" /4" Series Reference d I L D F H Series Reference d I L D F H MT MT MT / F F " / Fixed Broaching Heads VDI shank Series Reference D d1 d F H 9R.0.1 VDI F1 9R.30.1 VDI R.40.1 VDI F16 9R VDI R VDI

4 Broaching Bits Hexagon F D F D1 F1 D1 F F Imperial / / / / Standard Hexagon Broaching Bits will broach to a depth of the AF size + 0% 5

5 Broaching Bits Square F5 D F D1 F F

6 Broaching Bits Torx* Series Reference F H P S R Torx* Series Reference F H P S R Torx* D D External Broaching Adaptors * Torx: Registered by Textron Inc. USA Broaching Bits are availalble with TiN or BLK coatings to order External Broaching Bits Available sizes Hexagon 3 to 0mm AF & Square 3 to 18mm AF 7

7 CUTTING DATA Recommended Parameters Feed per RPM (mm) Material Hexagon Square Torx <14mm >14mm <1mm >1mm <T5 >T7 Free Cutting Steel Rm <700 N/mm Steel Rm N/mm Steel Rm N/mm High Strength Steel Rm N/mm Stainless Rm >8 N/mm Grey Cast Iron Rm <600 N/mm Malleable Cast Iron Rm N/mm Aluminium, long chipping Rm <0 N/mm Aluminium, short chipping Rm <0 N/mm Soft Brass/Copper Rm <700 N/mm Hard Brass short chipping Rm<700 N/mm Titanium Alloys Rm <700 N/mm CUTTING DATA: Rotation speed rpm. For best results it s advisable to start the broaching phase at slow rotation or fast feed for the first 0.5mm then revert to the recommended parameters (when the Broaching Bit is in full contact with the workpiece). When feeding out after broaching us a fast but not rapid feed rate. The type of material to be processed is a major factor in the choice of the feed rates together with the amount of material to be removed, the rigidity of the set-up. To reduce processing times, (still maintaining a good finish and low wear of the tool and of the bearings), you can increase rpm whilst reducing the feed. DRILLING: Centre drill (60 or 45 ) 0.5mm, larger than the across corner size. For hexagons; pre-drill size by +1%/4%. For Squares: pre-drill size by +3%/1%. Length of the hole; Drill 30-40% deeper than the feature. BROACH CENTRING: To obtain a good finish, low wear of the tool and of the bearing and no spiraling it s necessary for the broaching bit to be on centreline with the workpiece. If the machine can t be used to centre then it s advisable use the adjustable broaching head. Tooling Ltd Access House Read Street Coventry CV1 5PT Tel Fax info@bluechiptooling.co.uk 8