Operating broaching machines

This standard identifies the competences you need to carry out machining operations on a broaching machine, in accordance with approved procedures. You will confirm with the machine setter that the machine is ready for the operations to be performed and that all the required components/materials and consumables are available. You will be expected to produce a range of components that cover a number of different features, such as keyways, square holes, hexagonal and octagonal holes, holes with a single flat side, splines, serrations and special forms.

You will be required to operate the machine in line with safe working practices and approved procedures, to continuously monitor the machining operations and, where necessary, make minor adjustments or seek the help of the setter to make the required adjustments, in order to ensure that the work output is to the required quality and accuracy. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.

Your responsibilities will require you to comply with organisational policy and procedures for the machining activities undertaken, and to report any problems with the machining activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will enable you to adopt an informed approach to applying broaching procedures. You will have an understanding of the broaching process and its application, and will know about the equipment, materials and consumables in adequate depth to provide a sound background for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the machine, its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Setting up of the machine, its tooling and associated workholding devices, is the subject of another standard and is the responsibility of the machine-tool setter.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. confirm that the machine is set up and ready for the machining activities to be carried out
3. operate the machine tool controls safely and correctly in line with operational procedures
4. produce components to the required quality and within the specified dimensional accuracy
5. carry out quality sampling checks at suitable intervals
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. complete the required production documentation
8. shut down the equipment to a safe condition on conclusion of the machining activities

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1. the safe working practices and procedures to be followed whilst operating broaching machines
2. the safety mechanisms on the machine, and the procedure for checking that they function correctly
3. operation of the machine controls in both hand and power modes, and how to stop the machine in an emergency
4. the personal protective equipment (PPE) to be worn, and where this can be obtained
5. the hazards associated with the broaching operations (such as moving parts of machines, handling broaches, handling cutting oils, insecure components, breakages of broaches), and how to minimise them and reduce any risk
6. the importance of keeping the work area clean and tidy
7. where to obtain the component drawings, specifications and/or job instructions required for the components to be machined
8. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
9. how to use imperial and metric systems of measurement
10. the various broaching techniques that can be used to produce the required shapes, and the types of broaches used (roughing and finishing broaches, high speed steel and tipped broaches)
11. how to handle and store broaches safely and correctly
12. the application of cutting fluids with regard to a range of different materials
13. the effects of clamping the work piece, and how this can cause distortion in the finished components
14. how to recognise broaching faults, and how to identify when tools need re-sharpening
15. the quality control procedures used, inspection checks to be carried out, and the equipment that will need to be used
16. the problems that can occur with the broaching activities, and how these can be overcome
17. the extent of your own authority and to whom you should report if you have problems that you cannot resolve

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1. Apply all of the following during the machining activities:

   1. obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. confirm with the machine setter that the machine is ready for production
   4. where appropriate, seek any necessary instruction/training on the operation of the machine
   5. ensure that machine guards are in place and are correctly adjusted
   6. hold components securely, without distortion
   7. follow the defined operating procedures and apply safe working practices and procedures at all times
   8. ensure that machine settings are adjusted as and when required (either by yourself or the setter) to maintain the required accuracy
   9. ensure that the components produced meet the required specification for quality and accuracy
   10. leave the work area and machine in a safe and appropriate condition on completion of the activities

2. Operate one type of broaching machine from the following:

   1. horizontal broaching machine
   2. vertical broaching machine

3. Produce machined components which cover three of the following:

   1. keyways             
   2. octagonal holes
   3. flat sided holes   
   4. splines
   5. square holes       
   6. serrations
   7. hexagonal holes    
   8. other/special forms

4. Machine components made from one type of material from the following:

   1. ferrous
   2. non-ferrous
   3. non-metallic

5. Use appropriate gauges or instruments to carry out the necessary checks, during production, for accuracy of three of the following:

   1. dimensions      
   2. surface finish
   3. squareness         
   4. keyway width
   5. spline/serration fit   
   6. keyway position

6. Produce components with dimensional accuracy, form and surface texture within all of the following quality and accuracy standards:

   1. dimensional tolerance equivalent to BS EN 20286 or BS 1916 Grade 9
   2. surface finish 63µin or 1.6µm
   3. components to be free from false tool cuts, burrs and sharp edges

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2

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31 Mar 2019

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Current

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Original

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Semta

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SEMMME2-15

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5221

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engineering; manufacturing; mechanical; machining; operating; broaching machines; horizontal broaching machines; vertical broaching machines; keyways; multi-sided holes

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