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
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 175.10 MT 68 175.0 MT 68 175.110 10 175.19 3/4" D8 175.11 1 175.0 0 35 175.115 5/8 D1 175.5 5 175.116 16 34 8 30 175.6 1 5 6 1 40.5 175.119 3/4" 175.31 1.1/4 175.10 0 175.3 3 46 175.15 5 175.16 1 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
Fixed Broaching Heads cylindrical shank Series Reference d I L D F H Series Reference d I L D F H 175.8 8 175.60 MT 69 F5 175.510 10 175.610 10 175.51 1 35 175.61 1 175.515 5/8 34 5 10 175.615 5/8 35 175.516 16 F8 175.616 16 38 3 8 18 175.519 3/4" 175.619 3/4" 46 175.10 0 175.60 0 175.65 5 175.66 1 Series Reference d I L D F H Series Reference d I L D F H 175.70 MT 69 175.803 MT3 85 175.716 16 175.804 MT4 109 175.719 3/4 175.80 0 F1 175.70 0 46 44 1 5 175.85 5 F16 175.75 5 175.86 1 76 58 16 40 175.76 1" 175.831 1.1/4 175.73 3 175.83 3 175.840 40 80 Fixed Broaching Heads VDI shank Series Reference D d1 d F H 9R.0.1 VDI0 44 1 5 F1 9R.30.1 VDI30 58 68 9R.40.1 VDI40 83 40 F16 9R.30.16 VDI30 68 16 5 9R.40.16 VDI40 83 40 4
Broaching Bits Hexagon 8030010 1.0 8010010 1.0 8030015 3 1.5 8010015 3 1.5 803000 3.5.0 801000 3.5.0 803005 4.5 801005 4.5 8030030 5 3.0 8010030 5 3.0 F5 5 10 8030035 3.5 D8 8010035 6 3.5 8 18 8030040 4.0 F8 8010040 6.5 4.0 80300 6 5.0 80100 8.5 5.0 8030055 5.5 8010055 9.5 5.5 8030060 6.0 8010060 10.5 6.0 8010070 1 7.0 8010080 1.5 8.0 D1 F1 D1 F1 8000010 1.0 800030 5 3.0 8000015 3 1.5 800035 6 3.5 800000 3.5.0 800040 6.5 4.0 800005 4.5 8000 8.5 5.0 8000030 5 3.0 800060 10.5 6.0 8000035 6 3.5 800070 13 7.0 8000040 6.5 4.0 800080 15.5 8.0 80000 8.5 5.0 800090 17.5 9.0 8000055 8.5 5.5 800100 18.5 10.0 8000060 1 5 10.5 6.0 800110 0 11.0 8000070 13 7.0 80010 0 1.0 8000080 15.5 8.0 800130 8 13.0 F16 16 40 8000090 9.0 800140 14.0 8000100 10.0 8001 15.0 8000110 11.0 800160 16.0 800010 1 1.0 800170 17.0 8000130 13.0 800180 18.0 8000140 14.0 800190 19.0 3 80001 15.0 80000 0.0 800003175 Imperial 80010 1.0 6 1/8 8000.0 8000063 10.5 1/4 80030 3.0 1 5 80000955 3/8 80040 4.0 1 80001700 1/ 800 5.0 Standard Hexagon Broaching Bits will broach to a depth of the AF size + 0% 5
Broaching Bits Square 8031010 1.0 801100 3.5.0 8031015 3 1.5 801105 4.5 803100 3.5.0 8010030 5 3.0 803105 4.5 8010035 6 3.5 F5 D8 8031030 5 3.0 8011040 8 18 6.5 4.0 5 10 F8 8031035 3.5 80110 8.5 5.0 8031040 4.0 8011055 9.5 5.5 80310 6 5.0 8011055 10.5 6.0 8031055 5.5 8011070 1 7.0 8031060 6.0 D1 F1 800100 3.5.0 801030 5 3.0 800105 4.5 801040 6 4.0 8001030 5 3.0 8010 6.5 5.0 8001035 6 3.5 801060 8.5 6.0 8001040 6.5 4.0 801070 10.5 7.0 80010 8.5 5.0 801080 13 8.0 8001055 8.5 5.5 801090 15.5 9.0 8001060 1 5 10.5 6.0 801100 17.5 10.0 8001070 13 7.0 801110 18.5 11.0 8001080 15.5 8.0 80110 0 1.0 8001090 9.0 801130 0 13.0 8001100 10.0 F16 801140 16 40 8 14.0 8001110 1 11.0 8011 800110 1.0 801160 16.0 8001130 13.0 801170 17.0 15.0 801180 18.0 801190 19.0 80100 3 0.0 80110 1.0 8010.0 80130 3.0 80140 4.0 801 5.0 6
Broaching Bits Torx* Series Reference F H P S R Torx* Series Reference F H P S R Torx* D8 80106 0.-0.70 1.80 1.9 6 80006 0.-0.70 1.80 1.9 6 80108 0.70-0.90.45 1.80 8 80008 0.70-0.90.45 1.80 8 80110 1.00-1.30.85.07 10 80010 1.00-1.30.85.07 10 80115 1.30-1. 3.38.44 15 80015 1.30-1. 3.38.44 15 8 18 8010 1.-1.60 3.96.86 0 8000 1.-1.60 3.96.86 0 8015 1.60-.00 4.55 3.8 5 D1 8005 1 5 1.60-.00 4.55 3.8 5 8017.00-.40 5.10 3.65 7 8007.00-.40 5.10 3.65 7 80130.60-3.00 5.65 4.07 30 80030.60-3.00 5.65 4.07 30 External Broaching Adaptors * Torx: Registered by Textron Inc. USA Broaching Bits are availalble with TiN or BLK coatings to order 80040 3.00-3.30 6.80 4.88 40 80045 3.-4.00 7.97 5.68 45 800 4.00-4. 8.99 6. External Broaching Bits Available sizes Hexagon 3 to 0mm AF & Square 3 to 18mm AF 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 0.10 0.08 0.06 0.04 0.10 0.08 Steel Rm 700-8 N/mm 0.08 0.06 0.05 0.03 0.08 0.06 Steel Rm 8-100 N/mm 0.06 0.03 0.03 0.0 0.05 0.03 High Strength Steel Rm 100-1400 N/mm 0.0 0.0 0.0 0.0 0.03 0.0 Stainless Rm >8 N/mm 0.04 0.03 0.03 0.0 0.04 0.03 Grey Cast Iron Rm <600 N/mm 0.11 0.08 0.07 0.04 0.11 0.08 Malleable Cast Iron Rm 600-1000 N/mm 0.07 0.05 0.04 0.03 0.07 0.05 Aluminium, long chipping Rm <0 N/mm 0.14 0.10 0.10 0.08 0.14 0.10 Aluminium, short chipping Rm <0 N/mm 0.10 0.08 0.08 0.06 0.10 0.08 Soft Brass/Copper Rm <700 N/mm 0.1 0.09 0.10 0.08 0.1 0.10 Hard Brass short chipping Rm<700 N/mm 0.08 0.06 0.07 0.05 0.08 0.06 Titanium Alloys Rm <700 N/mm 0.03 0.0 0.0 0.0 0.03 0.0 CUTTING DATA: Rotation speed 1000-0 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 04 7647 4819 Fax 04 7647 480 info@bluechiptooling.co.uk www.bluechiptooling.co.uk www.mazaktooling.co.uk 8