Broaching is a _____ that uses a toothed tool to remove the material from the workpiece.

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RRB JE CBT 2 (Mechanical Engineering) ReExam Official Paper (Held On: 04 Jun, 2025)

Answer 1

Explanation:

Broaching Process:

Broaching is a machining process that involves the use of a multi-toothed cutting tool called a broach to remove material from a workpiece. The process is designed to perform precision machining operations, such as shaping, sizing, or finishing, in a single pass. Broaching is particularly well-suited for applications where high accuracy, good surface finish, and complex profiles are required.
The broaching process is performed by moving the broach either linearly (linear broaching) or rotationally (rotary broaching) relative to the workpiece. The broach consists of a series of cutting teeth arranged in a specific sequence, with each tooth progressively increasing in size. This arrangement allows the broach to remove material gradually, resulting in a smooth and accurate cut.

Key Features of Broaching:

High Precision: Broaching provides excellent dimensional accuracy and surface finish, making it ideal for applications where tight tolerances are required.
Complex Shapes: The process can produce intricate and non-circular shapes, such as splines, keyways, and gears, that are difficult to achieve with other machining methods.
Efficiency: Broaching is a fast and efficient process, as it completes the machining operation in a single pass.
Versatility: It can be used on various materials, including metals, plastics, and composites.
Tool Design: The broach is designed with a gradual increase in tooth height, which minimizes cutting forces and reduces the risk of tool wear and breakage.

Types of Broaching:

Internal Broaching: Used to create internal features, such as holes, keyways, and splines, within a workpiece.
External Broaching: Used to machine external surfaces, such as flat, contoured, or cylindrical features.
Linear Broaching: The broach moves linearly relative to the workpiece.
Rotary Broaching: The broach rotates relative to the workpiece, often used for machining hexagonal or other non-circular holes.

Applications of Broaching:

Manufacturing of gears, splines, and keyways.
Creating complex profiles in automotive, aerospace, and industrial components.
Producing high-precision parts for medical devices and other specialized industries.