Gibbscam - Introduction to Broaching

Version 14 : September 2020 Broaching Contents Introduction to Broaching 4 Tools for Broaching 4 Broaching Tool Dialogs 4 4 5 Controls in Broaching Tool Dialogs Parameters for 2D and 3D Form Tools Broaching Tool Definition 6 6 Side and Shank Definition Linear Broaching Tools Rotary Broaching Tools 7 9 Broaching Processes 11 Linear Broaching Processes 11 11 12 16 16 Linear Broaching Process Diagram Strategies and Illustrations Stock Controls Common Controls Rotary Broaching Process 18 Rotary Broaching Process Dialog Feeds and Speeds Clearance Diagram Machine controls Face Broaching 18 19 19 19 20 CONVENTIONS 21 21 21 Text Graphics LINKS TO ONLINE RESOURCES 3 22 Introduction to Broaching Broaching is used for high quality precision machining of non-circular shapes, such as hexagons or keyways. GibbsCAM supports both Linear (Oriented) and Rotary (Face or wobble) broaching LicensingIf you have Turning, you automatically have Face Broaching. If you have Advanced CS, you automatically have Oriented Broaching. Please Note: This feature requires a post upgrade. To request a post upgrade, contact your Reseller or the Gibbs Post Department. Tools for Broaching Broaching Tool Dialogs Linear Broaching Tool Rotary Broaching Tool Controls in Broaching Tool Dialogs 1. Enter the correct values in both the End and Side views of a broaching tool to fully define the tool. 2. Enter details of your Toolholder and Toolblock, if used. The system will calculate holder offsets using this data. For more information on offsets, see the see the Mill guide's discussion of Mill Tool Offset Data. 4 On turning machines, a broaching tool requires a special toolholder that allows it to rotate in sync with the workpiece. Different broaching tools are used for ID and OD broaching. 3. Define the Tooltype-specific values (see tools). The tool diagram and specifications depend on the tool type selected. The shaded sections of a tool diagram illustrate the cutting surfaces of a tool. The grey areas are non-cutting surfaces of the tool. If these surfaces come into contact with a part, the system draws this contact area in red during rendering to show interference. 4. Specify Linear/Rotary broaching general parameters as follows: Setup Orientation Angle (Linear only) Enter an orientation angle if required. Tool Length Offset number This number designates the numeric location in the machine where the Z offset amount is entered. Length out of Holder If there is a tool holder, this is the tool length measured from the front end of the holder. If there is no holder, enter the tool length measured from the tool attachment point. Parameters for 2D and 3D Form Tools Nominal Diameter Enter the overall diameter of the tool. If the shape is to be duplicated, this would be the diameter of the final tool. Tip Offset Distance This is the distance between the shank center and the tool tip. Duplication Type In order to create custom tools, the form tool shape can be repeated around a circle. Select the duplication required: None No duplication. Full Circle Creates equally spaced duplicates around a full 360 degrees. Enter the Total number of duplicates. Partial Circle Enter the number of duplicates. Enter the angle between each shape. The angle can be positive or negative. A positive value duplicates in a counterclockwise direction, a negative value in a clockwise direction. 5 Broaching Tool Definition To fully define a broaching tool, use the two radio buttons: One defines the side view of the tool. The other to define the bottom (cutting area of the tool). Side and Shank Definition 1. 2. 3. 4. 5. End view of broaching tool (tool-specific values Side view of broaching tool Shank diameter Total tool length Cut length A broaching tool is created by extruding the cut end shape by the cut length amount along the tool axis. A cylindrical shank is then added. This dialog enables the shank and side view of the tool to be defined. 6 Linear Broaching Tools GibbsCAM v14 supplies templates for seven linear broaching tools. Cutting end definition for linear broaching tools icons Name End View Notes 1. Dimension across Flats 2. Across Corners (calculated) 3. Check to add Corner radius Linear Hexagon Broach 1. 2. 3. 4. Linear Keyway Broach Linear Chamfer Broach Linear Corner Broach Width Side to side diameter Top to bottom Height Check to add Corner radius 1. 2. 3. 4. Side length of Chamfer Width of keyway Side to side diameter Top to bottom Height 1. 2. 3. 4. Length of edge Included angle (degrees) Top to bottom Height Distance between shank center and Tool tip Linear Hexalobular Broach 1. Tool size Linear 2D Form Broach Custom dimensions 7 Linear 3D Form Broach Custom dimensions 8 Rotary Broaching Tools GibbsCAM v14 supplies templates for seven rotary broaching tools. Cutting end definition for rotary broaching tools icons Name End View Notes Rotary Hexagon Broach 1. Diameter measured across flats 2. Across Corners (calculated) 3. Check to add Corner radius Rotary Double Hexagon Broach 1. Diameter measured across flats 2. Across Corners (calculated) 3. Check to add Corner radius Rotary Rectangle Broach 1. Side to side width 2. Top to bottom Height 3. Check to add Corner radius Rotary Hexalobular Broach 1. Tool size Rotary 2D Form Broach Custom dimensions Rotary 3D Form Broach Custom dimensions 9 1. Internal diameter measured across flats 2. Across corners (calculated) 3. External diameter 4. Check to add Corner radius Rotary External Hexagon 10 Broaching Processes Linear Broaching Processes Linear Broaching processes cut a small amount of material at a time by pushing the tool into the material. Many passes are usually required to create the desired shape. Linear Broaching Process Diagram When a Linear broaching function tile is combined with a linear tool from the Broaching tool list, a process dialog will appear. The exact dialog will differ with the tool selected and the strategy chosen. The illustration diagram will also change to provide information on input required for Clear Amount, First and Final Step, and Desired Stepover. 1. Strategy 2. (illustration; varies with strategy) 3. (strategy-specific controls) 4. Stock control 5. Controls common to all strategies 11