Hi all,
We currently have a part we run that has a broached hex put into it. Currently we run 3 varied sizes of this part. ON the smallest part we punch broach from the 20 tools into material gripped by the main spindle. On the larger sizes we use a stepped pickoff collet and broach from the 30 tools into the back spindle. We are considering buying another L7 to replace one of our L5's and the owner has some concerns about broaching with a new machine.
Currently on our largest part we actually grind off 3 of the corners our broaching tool and index the part and punch it multiple times. This works somewhat ok to relieve some of the pressure needed.
We would use a rotary broach, but this part also requires that the hex be oriented against another part feature (Drilled hole during main operation) and we are not aware of any way that would accurately orient a rotary broach between parts.
I was hoping someone may have any suggestions on tooling or processes we're unaware of that may help. We are only broaching a countbore that is approximately .040-.050 deep.
Picture a stepped .500 OD washer .200 in lenght with a .400 square shoulder bore to a .170 depth. The remaining .030 is what we broach--and we do pre-drill it to the largest size allowed by the hex flats.
Any suggestion/information is well appreciated--even if I don't get a chance to respond for a while.