Our CNC Broaching Services
Looking for precision CNC Broaching that blends efficiency, consistência, e custo-efetividade? Our CNC Broaching services leverage advanced Técnicas de fabricação and decades of expertise to deliver custom solutions for industries ranging from automotive to medical. Whether you need intricate internal gears or high-tolerance keyways, we turn your specifications into high-quality parts—on time, toda vez.
What Is CNC Broaching?
Brochamento CNC é um especializado processo de corte in machining that uses a toothed tool called a Broaching Tool to remove material from a workpiece, criando preciso, formas complexas (such as keyways, splines, engrenagens, or slots) in a single pass. Unlike manual broaching, CNC (Controle numérico do computador) broaching uses computer programs to control the tool’s movement, garantindo precisão e repetibilidade incomparáveis.
Na sua essência, o conceito of CNC Broaching revolves around efficiency: instead of multiple setup changes for different cuts, o Broaching Tool (which has teeth increasing in size) completes the entire cut in one operation. This makes it ideal for high-volume production while maintaining strict quality standards.
| Termo -chave | Meaning | Role in CNC Broaching |
| CNC Broaching | Computer-controlled broaching process | Automates tool movement for precision and consistency |
| Broaching Tool | Toothed cutting tool with progressively sized teeth | Removes material to create desired shapes in one pass |
| Cutting Process | Material removal via tool-workpiece interaction | Core operation that shapes the final part |
Nossas capacidades: What We Offer in CNC Broaching
Our team brings together years of experiência and technical especialização to handle even the most demanding CNC Broaching projects. We don’t just offer standard services—we tailor solutions to your unique needs, ensuring every part meets your exact specifications.
Our Core CNC Broaching Capabilities
| Capacidade | Detalhes | Aplicações típicas |
| Custom Broaching | Design and produce broaching tools for unique part geometries (Por exemplo, non-standard splines, custom keyways) | Componentes do motor aeroespacial, medical device fittings |
| Precision Broaching | Achieve dimensional tolerances as tight as ±0.0005” (0.0127 milímetros) and surface roughness down to Ra 0.8 μm | High-precision gears for robotics, conectores eletrônicos |
| Range of Services | Internal broaching (keyways, splines), external broaching (engrenagens, slots), and surface broaching | Automotive transmissions, Eixos de máquinas, construction equipment parts |
| Produção de alto volume | Process up to 500 parts per shift with consistent quality | Mass-produced automotive keyways, Componentes do aparelho |
With a team of certified engineers and state-of-the-art CNC broaching machines, we’ve successfully delivered projects for clients in 12+ industries—proving our ability to scale from small-batch prototypes to large-scale production runs.
Processo: How CNC Broaching Works
O CNC Broaching Process is streamlined and efficient, com claro passos that minimize setup time and maximize accuracy. Unlike other machining methods (Por exemplo, milling or turning), broaching relies on a linear tool path to create complex shapes in one go.
Step-by-Step CNC Broaching Operation Procedure
- Configuração da máquina: The workpiece is clamped securely in a fixture, and the CNC program (which defines the tool path e parâmetros de corte) is loaded into the machine. Our technicians calibrate the machine to ensure alignment with the workpiece’s reference points.
- Preparação de ferramentas: The appropriate Broaching Tool (selected based on material, geometria de parte, and tolerance requirements) is mounted onto the machine’s spindle. Tools are inspected for sharpness and wear before each run.
- Cutting Sequence: The CNC machine moves the Broaching Tool linearly across (or into) a peça de trabalho. Each tooth on the tool removes a small amount of material—starting with the smallest tooth and ending with the largest, which achieves the final shape.
- Verificação de qualidade: After the cut is complete, the workpiece is removed and inspected for dimensional accuracy and surface finish using precision measuring tools (Por exemplo, micrômetros, Cmms).
- Ejeção de peça & Next Cycle: The finished part is ejected, and the machine resets for the next workpiece—all automated to reduce downtime.
The entire process typically takes 30 segundos para 2 minutos por parte, depending on the complexity—making it far faster than multi-step machining methods.
Materiais: What Can We Broach?
CNC Broaching works with a wide range of materials, from soft plastics to hard alloys. The choice of material depends on the part’s end-use (Por exemplo, strength for automotive parts, corrosion resistance for medical devices) and determines the Broaching Tool type and cutting parameters.
Common Materials for CNC Broaching
| Tipo de material | Exemplos | Propriedades -chave | Aplicações ideais |
| Metais | Aço (leve, liga, inoxidável), Alumínio | Aço: Alta resistência; Alumínio: Leve, boa condutividade térmica | Aço: Eixos de engrenagem, Suportes de construção; Alumínio: Gabinetes eletrônicos, Aparelho automotivo |
| Ligas | Liga de titânio, Brass alloy, Copper alloy | Titânio: Alta proporção de força / peso; Latão: Resistente à corrosão, boa máquinabilidade | Titânio: Componentes aeroespaciais; Latão: Acessórios de encanamento, conectores elétricos |
| Plástico | Nylon, Espiar, Acetal | Leve, resistente à corrosão, baixo atrito | Componentes de dispositivos médicos, peças eletrônicas de consumo |
We test each material with sample cuts to optimize the processo de corte—ensuring minimal tool wear and maximum part quality. Por exemplo, when broaching stainless steel (um material difícil), we use carbide Broaching Tools and slower cutting speeds to maintain precision.
Tratamento de superfície: Aprimorando o desempenho da peça
After CNC Broaching, tratamento de superfície (ou acabamento) is often applied to improve the part’s durability, aparência, ou funcionalidade. The right treatment depends on the material and the part’s end-use (Por exemplo, heat treatment for strength, plating for corrosion resistance).
Our Surface Treatment Options
| Tipo de tratamento | Processo | Benefícios | Casos de uso típicos |
| Tratamento térmico | Heating and cooling the part to alter its microstructure (Por exemplo, recozimento, Tireização) | Aumenta a dureza, força, and wear resistance | Engrenagens automotivas, machinery shafts |
| Revestimento | Depositing a thin layer of metal (Por exemplo, cromo, níquel, zinco) onto the part’s surface | Melhora a resistência à corrosão, condutividade, and appearance | Conectores elétricos, componentes marinhos |
| Revestimento | Applying a protective layer (Por exemplo, cerâmica, Ptfe) | Reduz o atrito, enhances chemical resistance | Dispositivos médicos, válvulas industriais |
| Pintura | Applying a decorative or protective paint layer | Improves aesthetics and prevents rust | Consumer-facing parts (Por exemplo, appliance handles) |
We work with trusted surface treatment partners to ensure consistency—for example, our zinc-plated parts meet ASTM B633 standards, providing up to 1,000 hours of corrosion resistance in salt spray tests.
Tolerâncias: The Precision We Deliver
Tolerâncias are critical in CNC Broaching—even small deviations can affect a part’s performance (Por exemplo, a loose keyway in a gear shaft can cause machinery failure). Our process is optimized to achieve tight dimensional tolerance and smooth rugosidade da superfície, meeting or exceeding industry standards.
Nossas capacidades de tolerância vs. Médias da indústria
| Métrica | Nossa capacidade | Média da indústria | Vantagem |
| Tolerância dimensional | ± 0,0005 ” (0.0127 milímetros) | ±0.0015” (0.0381 milímetros) | 3x tighter tolerance for high-precision parts |
| Rugosidade da superfície (Rá) | 0.8 – 3.2 μm | 3.2 – 6.3 μm | Smoother surface for reduced friction and improved aesthetics |
| Positional Tolerance | ± 0,001 ” (0.0254 milímetros) | ±0.003” (0.0762 milímetros) | More accurate part alignment for assembly |
Para manter essas tolerâncias, we use CNC machines with linear encoders (precisão: ±0.0001” per foot) and perform in-process inspections every 20 peças. This ensures consistência across even large production runs.
Vantagens: Why Choose CNC Broaching Over Other Methods?
CNC Broaching offers unique benefícios that make it superior to traditional machining methods (Por exemplo, moagem, modelagem) for many applications. Its combination of efficiency, precisão, and cost-effectiveness makes it a top choice for manufacturers.
Key Advantages of CNC Broaching
| Vantagem | Descrição | Impact on Your Project |
| Alta eficiência | Completes complex cuts in one pass (vs.. 3–5 passes for milling) | Reduces production time by 50–70% |
| Precisão & Consistência | CNC automation eliminates human error; parts have identical dimensions | Reduces scrap rate to <1% (vs.. 3–5% for manual methods) |
| Econômico | Fewer setup changes and less labor mean lower per-part costs—especially for high volumes | Saves 20–30% on production costs for runs of 1,000+ peças |
| Time-Saving | Tempos de ciclo rápido (30 sec–2 min per part) and minimal downtime | Meets tight deadlines for urgent orders |
| Complex Shape Capability | Creates intricate shapes (Por exemplo, internal splines, blind keyways) that are hard to achieve with other methods | Eliminates the need for secondary operations (Por exemplo, moagem) |
Por exemplo, a client producing automotive transmission shafts switched from milling to our CNC Broaching service and cut their production time from 10 minutes per part to 90 seconds—while reducing scrap from 4% para 0.5%.
Indústria de aplicativos: Where CNC Broaching Is Used
CNC Broaching is a versatile process used in nearly every manufacturing sector. Its ability to create precise, complex parts makes it indispensable for industries that demand high performance and reliability.
Industry Applications of CNC Broaching
| Indústria | Common Broached Parts | Why CNC Broaching Is Ideal |
| Automotivo | Keyways in transmission shafts, splines in axles, gears in engines | High-volume production needs; requires consistent precision for safety-critical parts |
| Aeroespacial | Turbine blade roots, aircraft engine gears, hydraulic valve slots | Demands ultra-tight tolerances (± 0,0005 ”) and high-strength materials (ligas de titânio) |
| Eletrônica | Connectors with internal slots, heat sink fins, Altas do sensor | Needs small, precise parts and fast production for consumer electronics |
| Médico | Componentes do instrumento cirúrgico (Por exemplo, forceps slots), implant parts (Por exemplo, hip implant splines) | Requires biocompatible materials (Por exemplo, aço inoxidável) e acabamentos de superfície lisa (Rá <1.6 μm) |
| Máquinas | Eixos de engrenagem, Molas de rolamento, conveyor chain links | Needs durable parts that can withstand heavy loads; CNC broaching ensures long part life |
| Construção | Hydraulic cylinder keyways, crane gear teeth, scaffolding connectors | Requires large, strong parts with consistent dimensions for structural safety |
In the aerospace industry alone, our CNC Broaching services have helped clients produce parts that meet AS9100 standards—critical for airworthiness.
Técnicas de fabricação: The Technology Behind Our CNC Broaching
Our CNC Broaching relies on advanced Técnicas de fabricação and tooling to deliver superior results. We combine proven broaching methods with modern CNC technology to optimize every step of the process.
Core Manufacturing Techniques
| Técnica | Como funciona | Benefício |
| Integração de usinagem CNC | Our broaching machines are linked to CAD/CAM software, allowing us to import your 3D models directly and generate tool paths automatically | Reduces setup time by 40%; ensures parts match your design exactly |
| High-Speed Broaching | Uses high-speed steel (HSS) or carbide tools with optimized cutting angles to increase feed rates (até 500 mm/min) | Cuts cycle time by 30% without sacrificing precision |
| Tooling Optimization | We design custom Broaching Tools para peças únicas (Por exemplo, variable-pitch teeth for reducing vibration) | Improves surface finish and extends tool life (até 5,000 peças por ferramenta) |
| Automated Load/Unload Systems | Robotic arms load and unload workpieces, eliminating manual handling | Increases production capacity by 25%; reduces labor costs |
We also invest in ongoing training for our technicians to stay updated on the latest broaching techniques—ensuring we always use the most efficient, cost-effective methods for your project.
Estudos de caso: Success Stories From Our Clients
Our CNC Broaching services have helped clients across industries solve complex manufacturing challenges. Below are two real-world examples of how we delivered results.
Estudo de caso 1: Automotive Transmission Parts
Cliente: A leading automotive parts manufacturer producing 50,000 transmission shafts per month.
Desafio: Their existing milling process took 10 minutes per shaft, com um 4% scrap rate—causing delays and high costs.
Solução: We implemented CNC Broaching with custom carbide tools and automated load/unload systems.
Resultados:
- Tempo de ciclo reduzido para 90 seconds per shaft (75% mais rápido).
- Scrap rate dropped to 0.5% (saving $40,000/month in material costs).
- Met their monthly production target 2 weeks ahead of schedule.
Client Feedback: “The CNC Broaching service transformed our production line—we now have the capacity to take on larger orders without sacrificing quality.”
Estudo de caso 2: Medical Device Components
Cliente: A medical device company needing 1,000 custom hip implant splines (liga de titânio).
Desafio: The parts required a surface roughness of Ra 0.8 μm and dimensional tolerance of ±0.0003”—beyond their current capabilities.
Solução: We used precision CNC Broaching with diamond-coated tools and in-process CMM inspections.
Resultados:
- All parts met the tight tolerance and surface finish requirements.
- Delivered the order in 2 semanas (vs.. their previous supplier’s 4-week lead time).
- Parts passed FDA biocompatibility testing on the first try.
Client Feedback: “The attention to detail in the CNC Broaching process was unmatched—we now rely on them for all our high-precision medical parts.”
Por que nos escolher: Your Trusted CNC Broaching Partner
With so many CNC Broaching providers, Por que você deveria nos escolher? We stand out for our commitment to qualidade, serviço, and customer success—backed by decades of experience and proven results.
Principal 5 Reasons to Choose Our CNC Broaching Services
- Experiência incomparável: Nossa equipe tem 25+ years of combined experience in CNC Broaching—we’ve handled every challenge, from custom tool design to high-volume production.
- Controle de qualidade estrita: Nós somos ISO 9001 e certificado AS9100, with a 5-step inspection process (De matéria -prima à parte acabada) that ensures 99.9% part accuracy.
- Soluções personalizadas: We don’t offer “one-size-fits-all” services—we work with you to design custom broaching processes that meet your unique needs (Por exemplo, non-standard shapes, rare materials).
- Preços competitivos: Nossos processos eficientes (Por exemplo, sistemas automatizados, optimized tooling) let us offer cost-effective rates—saving you 20–30% vs. other providers.
Atendimento ao cliente excepcional: Atribuímos um gerente de projeto dedicado a todos os clientes, providing real-time updates and addressing issues within 24 horas. Nosso satisfação do cliente rate is 98%—and we’re proud of it.