The REV motorized broaching tool is designed for use on live tool lathes. Single machine set-up eliminates the need for secondary operation or outsourcing. REV tools are ideal for high production runs, offer easy installation and fast processing time. These tools are designed for maximum rigidity, offer long tool life and an excellent finish.

In total 16 vises are mounted on a 4th modified axis in a 3-axis machine. Thanks to the use of the compact vise SCHUNK KSC mini, the workpieces can be processed in one set up which results in a strong decline of run through time.

REV static broaching tools are for use on CNC lathes with or without Y-axis. They offer a patented eccentric bushing which eliminates alignment errors for machines without a Y-axis. The tools have a sturdy two-piece construction and are ideal for smaller runs. They are designed for use in boring bar holders on lathes and for use in collet chucks or Weldon holders on machining centers. REV tools allow for a wide variety of standard and custom profiles and sizes.

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Flexible-sided device that secures a tool or workpiece. Similar in function to a chuck, but can accommodate only a narrow size range. Typically provides greater gripping force and precision than a chuck. See chuck.

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Operation in which a cutter progressively enlarges a slot or hole or shapes a workpiece exterior. Low teeth start the cut, intermediate teeth remove the majority of the material and high teeth finish the task. Broaching can be a one-step operation, as opposed to milling and slotting, which require repeated passes. Typically, however, broaching also involves multiple passes.

Cone-shaped pins that support a workpiece by one or two ends during machining. The centers fit into holes drilled in the workpiece ends. Centers that turn with the workpiece are called “live” centers; those that do not are called “dead” centers.

Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.

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Cylindrical sleeve, typically made from high-grade tool steel, inserted into a jig fixture to guide cutting tools. There are three main types: renewable, used in liners that in turn are installed in the jig; press-fit, installed directly in the jig for short production runs; and liner (or master), installed permanently in a jig to receive renewable bushing.

Platinum Tooling, the importer and master distributor of live tools, angle heads, speed increasers, Swiss machine products, knurling and marking tools and shrink fit tool holders manufactured by various international suppliers, will now carry REV broaching tools in North America. This announcement was made by Platinum Tooling president, Preben Hansen, at their headquarters in Prospect Heights, Illinois, near Chicago.

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It is useful to observe the visible signs on the insert. This illuminates common failure modes, and helps to correct those failure modes that lead to under-performing cutting tools. The desired outcome is standard flank wear on the insert.Flank WearFlank wear is normal. All inserts will eventually wear out. The best situation is to have the insert wear through flank wear.  However, premature flank wear is not desired. The ideal situation is when it is possible to extend the life of the insert before flank wear causes failure, thus minimizing cycle time.The cause of flank wear is generally abrasive wear caused by the cutting speed, the hardness of the part, or a hard skin on the material being removed. Flank wear occurs when abrasion erodes the coating and eventually the substrate. The ideal flank wear is an even progression, making the process predictable.Some remedies to reduce flank wear are to select a grade that has more wear resistance. As a quick fix, one could simply slow the cutting speed, thereby increasing tool life but sacrificing cycle time. Of course, the best solution is to keep cycle time as short as possible. The long-term solution is to select a better grade.Notch WearNotch wear appears as a notch on the insert, generally at the depth of cut level. It is an oxidation at the depth of cut. This oxidation is caused by high temperatures and the presence of air. Tungsten and cobalt, the main ingredients in carbide inserts, form weak oxide films during oxidation.To remedy notch wear, select a more wear resistant grade. Generally inserts coated with Al2O3 which can help prevent oxidation of the substrate. As a quick fix one could increase the lead angle on the tool. This would ease the insert into the material and would also provide “chip thinning”. Another remedy would be to vary the depth of cut. In this way, the insert is not always cutting at the same depth of cut point. A variation of that method would be to make your first pass a taper and your next path a straight cut which would produce a constantly changing depth of cut.Crater WearCrater wear appears as a diffusion between the insert and the workpiece material. It occurs when enough thermal energy is created to enable the exchange of atoms across the tool-workpiece interface. The amount of diffusion depends on the chemical affinity between the two. For instance, tungsten and steel have a high chemical affinity. Effective remedies include using a lower cutting speed, or choosing a grade with more wear resistance. For instance, an Al2O3 coating helps to prevent diffusion and reduces crater wear.If you begin to lose chip control, check for crater wear because excessive types of this wear tend to change the edge geometry of the insert. Plastic DeformationCompression and heat, combined with high feeds and hard work materials, cause deformation of the insert edge. As edge deformation increases from the pressure, temperatures continue to rise, contributing to further deformation.Look for the edge to lose sharpness and bulge out when this happens.A quick fix is to reduce the speed or feed rate. But for long-term productivity, a more wear-resistant grade is key. Built-up edgeA built-up edge is when the workpiece material gets welded to the cutting edge. This usually occurs when cutting temperatures are too low. Additional chip flow is needed to avoid it. The remedies to this are to increase the cutting speed, and select a more positive insert geometry. Another remedy would be to increase the coolant flow to add lubricity. In the case of aluminum, use a polished insert to increase lubricity. In gummy steels, use a smooth, slippery coating.Thermal CrackingThermal Cracking is caused by abrupt temperature changes. A quick remedy is to turn the coolant off completely, or by drenching the tool in coolant to stabilize the temperature. Using a tougher, more wear-resistant grade is also an effective solution. When doing interrupted cutting, always run without coolant. ChippingChipping occurs when the insert edge breaks rather than wears. The fatigue associated with chipping is generally caused by temperature and force fluctuations. It usually means that the application is too demanding for the selected insert.To remedy this, it is necessary to select an insert with a stronger cutting edge. Also, try a tougher, more shock-resistant grade of carbideEdge FractureEdge fracture happens as a result of the other wear types. Remedy check all the cutting data and setup to consider what it might be. Once the edge fractures, the reason is unknown. Ideally, you want to check the insert before a fracture occurs to determine why such an incident might happen. The likely remedies for this are to reduce the feed rate, reduce the cutting speed, or select a tougher grade.John Mitchell, MBA, is the General Manager of Tungaloy Canada.

REV broaching tools are a perfect complement to the Heimatec live tools that are sold by the extensive network of Platinum Tooling manufacturers’ representatives and distributors throughout North America.

Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

Essentially a cantilever beam that holds one or more cutting tools in position during a boring operation. Can be held stationary and moved axially while the workpiece revolves around it, or revolved and moved axially while the workpiece is held stationary, or a combination of these actions. Installed on milling, drilling and boring machines, as well as lathes and machining centers.

Chipless material-displacement process that is usually accomplished on a lathe by forcing a knurling die into the surface of a rotating workpiece to create a pattern. Knurling is often performed to create a decorative or gripping surface and repair undersized shafts.

Failure analysis as it relates to cutting tools is an often-overlooked path to improving a machining process. Of course, eventually all cutting tools will fail, but failure analysis will help to optimize the output of the operation. Failure analysis works by checking the condition of the insert at a predetermined number of pieces. The condition of the insert would be analyzed at these checkpoints. The condition of the insert would be compared to typical failure modes, a diagnosis would be determined and adjustments would be made to maximize productivity. All too often a machine operator will bring a fractured insert to the tool crib and request more inserts. Once the insert has fractured, there are no clues as to the reason for the failure.Often in North America, tool life is simply measured by the amount of cut time, the number of parts or the distance the tool travelled while removing material. The determinant to indicate when the tool has reached its life expectancy is often the load on the spindle, the surface finish on the part or in some cases catastrophic failure. This is unfortunate, as the performance of the tool could be greatly enhanced with the proper diagnosis and alterations.In Japan, it is common to set predetermined checkpoints to inspect the insert. This is helpful, because one can see what is happening to the insert and make adjustments to optimize the tool’s output. Once the other failure modes have been corrected, measuring flank wear can then be the determinant of tool life.As mentioned earlier all inserts will wear out. However the ideal wear pattern is flank wear. By checking the insert at predetermined intervals, it is possible to see how the insert is wearing. There are many different types of wear patterns classified in failure analysis. Ultimately these failure modes – flank wear, notch wear, crater wear, plastic deformation, built up edge, thermal cracking, chipping and edge fracture – are symptoms of a shortened tool life. If the symptoms are recognized early, adjustments may be made to reach the desired outcome of flank wear.Some of the symptoms of tool wear are:

REV S.R.L., located in Northern Italy, is the manufacturer of innovative broaching solutions for CNC lathes and machining centers. The tools are ideal for machining simple keyways or internal and external profiles, both teeth and splines. Common profiles including square and hexagon are easily achieved and custom profiles are available. REV Broaching Tools offer excellent performance with long insert life and high surface quality.