Unlimited Innovative launches REV Broaching Tool in India
Un-limited Innovative Machining Solutions LLP, Mumbai based company that provides solutions in Back chamfering, deburring, cross holes, Titanium machining, turbine blade machining has recently launched the Italian tool broaching technology called REV Broaching Tool system in India.
F.P. Officina Meccanica, was founded in 1998 based on Mr. Paolo Franchini’s 18 years of experience in the mechanics industry. For many years, the company carried out slotting and broaching activities for third-parties, working in the hydraulic, automotive, biomedical, speed reducer, gear construction and earth moving machinery industries etc.
Introduction
The REV Broaching Tool system is an intelligent and efficient solution to carry out key housings and slotting directly on CNC lathes and machining centers , without having to set tools up on other machines and without having to hire external specialists. All of this while guaranteeing machining with an excellent finish, and always perfectly within tolerance. The REV Broaching Tool, also used on slotting and shaping machines, is a valid alternative to traditional tools, offering greater versatility and sturdiness. The REV system is the only one that provides customers with complete programme , cycle time calculation and tentative tool life for use on CNCs and that provides customers with technical assistance for their every demand, without any additional cost
The REV Broaching Tool can be used for processes requiring straight cuts, such as broaching tab or key housings, PTOs and internal gears, directly on CNC lathes, machining centers or milling machines, considerably faster and with remarkable precision. In addition to offering the significant advantage of not having to pick up the work piece for broaching or slotting and set it up on another dedicated machine, the tool also makes sure the broaching process is carried out correctly, at the same time as the other processes. Used on slotting or shaping machines, the REV tool represents an excellent substitute for traditional tools, as it offers greater versatility thanks to the re-usable tool body and the replaceable insert. The high rigidity of the REV Broaching Tool ensures that the sharp edge of the insert has an exceptionally long service life and that broaching or slotting is carried out perfectly in line with the axis of the work piece. The surface finish standard achieved through processing with this tool is very high. All of these characteristics together make the REV system among the most efficient and convenient mechanical precision processing systems currently available on the market. The REV Broaching Tool is available in various sizes, covering the entire range of the most common processing sizes, and each insert size can have various tolerance classes. Special insert measurements or tool shapes can be produced very rapidly, on customer demand.
Tools
The REV Broaching Tool is made with quenched and tempered tool steel. The section that houses the insert is hardened to 58/60 HRC, making it very resistant to compression and guaranteeing the tool a long service life. The REV Broaching Tool features 3.5 mm holes for the forced supply of coolant liquid which, in addition to lubricating and cooling the insert, are used to extract the chips, produced through broaching or slotting, out of the blind hole. The tool is available in two socket diameters (25 and 32). Two tool lines are available for each socket diameter: standard and long (identified by the suffix “L” in the code). We also produce special tools, based on customer demand, with great flexibility. The REV Broaching Tool differs from similar tools currently on the market by its patented eccentric bushing that completely eliminates symmetry errors. This bushing was provided so that any lathe without a Y-axis can perform processing in perfect alignment with the workpiece. The REV Broaching Tool guarantees low impact on the machine tool bearings. To date, none of the thousands of REV system users has reported issues of breakage or unusual wear caused by broaching on the CNC. Based on tests carried out by REV, the cutting force for executing key housings with a 20 mm width, for example, is comparable to the cutting force required for a common hole with a 14 mm diameter.
Processing
The processes that can be carried out with the REV Broaching Tool are, in terms of standard machining, all of those relative to broaching tab or key housings (with single or multiple timing, on cylindrical or conical holes, with or without a relief grooves, with or without 0.2mm x 45° chamfering on the base). With special tools it is also possible to execute PTOs, square, pentagonal and hexagonal holes and involute teeth, for example. 1 mm is the minimum hole size for broaching. The maximum processing depth is 200 mm, with standard machining. When it is necessary to execute considerably large key housings, it is good practice to perform the operation in two steps: a roughing phase to remove approximately 50% of the material, and a finishing phase to achieve the required size. Accordingly, you avoid excessive stress to the tool, and you improve precision and surface finish at the same time.
The materials that can be processed are:
• High and low-alloy low-carbon steel, and non-alloy steel;
• Stainless steel, quenched and tempered steel, cast iron, AVP;
• Non-ferrous materials such as aluminium alloys and titanium;
• Copper alloys, bronze, and engineering plastics.
Inserts
The broaching and slotting inserts are made with a sintered alloy which, following heat treatment, reaches a hardness of 72 HRC. This material gives the REV broaching inserts high toughness, and can accordingly withstand strong pressures, with the subsequent possibility of using increments of up to 0.2 mm on steel and 0.3 mm on cast iron without breakage during processing. These increments would not be possible if the inserts were manufactured with a different material, like the majority currently available on the market. The inserts are also subject to a surface treatment, TiN coating, with anti wear and seize properties. The inserts are re-sharpened by tapering their sides. This process eliminates any gouges that would prevent the insert from cutting perpendicular to the reference axis of the workpiece during the broaching phase. The protruding shape of the inserts makes it possible to re-sharpen them numerous times. All of these characteristics make REV inserts extraordinarily long-lasting. The inserts are available for immediate delivery in 27 sizes (considering millimetre and inch-based measurements), and 4 tolerance classes for each size (C11, D10, H7 and P6). Inserts measured in millilitres are identified by their code ending with “SM” and execute 0.2×45° chamfering on the intersection point between the hole and the walls of the broached slot, leaving the hole burr-free. This type of chamfering can only be carried out on UNI keys. We also manufacture special inserts on customer demand. Using re-sharpening machines for REV inserts, re-sharpening can be carried out with a standard grinding wheel. The re-sharpening machine has a comfortable grip and ensures that the insert protrudes from the rod, making the operation easier to perform.
Work parameters and performance
The cutting speed, the increase for each stroke and the service life of the cutting tool essentially depend on the material being processed.
The table below reports the operating conditions relative to some materials.
Savings & Advantages
- No inventory Cost of Broaches which is in lacs
- No wait time for Broach Re-sharpening
- Less Lead time of Procurement as delivery time for standard items only 10 days and for specials 3 weeks.
- Same machine which makes the Blank can do this operation, cost and time saving.
- LessCost due to damaged Broaches and accidental damages
Inhouse and easy regrind possible
Technical Advantage
In addition to making accurate profiles and forms the cutting forces are very low compared to wobbling broach method and low investment on the tools
