Setting broaching machines for production

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This standard identifies the competences you need to prepare and set up horizontal and/or vertical broaching machines for production, in accordance with approved procedures. This will involve selecting the appropriate workholding devices and securing them to the machine, and mounting and setting the workpiece in correct relationship to the broaching tool. You will be expected to select the appropriate broaching tools, check that they are in a usable condition, and mount and secure them to the relevant tool holding devices.

You will also need to set the machine operating parameters to produce the workpiece to the required specification. This will involve setting the appropriate stroke length, pulling pressure and feed required. You must produce trial cuts and prove that the machine is working satisfactorily before declaring the machine ready for production. Making adjustments to settings to achieve specification, and solving machine-related problems during production, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the machine setting activities undertaken, and to report any problems with the machine, tooling, equipment or setting up activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the setting up procedures used. You will understand the broaching machine used and its application, and will know about the workholding devices, broaching tools, relevant materials, consumables and setting up procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification.

You will understand the safety precautions required when working with the machine and 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.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct specifications for the component to be produced
3. determine what has to be done and how the machine will be set to achieve this
4. mount, set and secure the required workholding devices, workpiece and cutting tools
5. set the machine tool operating parameters to achieve the component specification
6. check that all safety mechanisms are in place and that the equipment is set correctly for the required operations
7. complete the required production documentation
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the hazards associated with setting broaching machines and how to minimise them and reduce any risks
3. how to start and stop the machine in normal and emergency situations
4. the importance of ensuring that the machine is isolated from the power supply before mounting broaching tools and workholding devices
5. the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy
6. the basic principles of operation of the broaching machine and its accessories, and typical operations that they can perform
7. how to handle and store broaching tools safely and correctly
8. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
9. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
10. terminology used in broaching in relation to the activities undertaken
11. the range of workholding methods and devices that are used on broaching machines
12. the methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used
13. the different types of broaching tools that are used, and how they are selected, prepared and mounted to the machine tool holding devices
14. factors which determine pulling pressure and feeds to be used
15. how the various types of materials will affect the feeds that can be used
16. the types of cutting fluid that are used, and precautions to be taken when handling and using them
17. how to set up the broaching machine and its accessories for the particular operations being performed
18. the need to conduct trial runs, and to check that the machine is set up and producing the components correctly
19. problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and what to do if problems occur
20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following activities during setting up:
   1. obtain and use the appropriate documentation
   2. adhere to procedures or systems in place for risk assessment,  personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. follow safe practice/approved setting up procedures at all times
   4. ensure that correctly adjusted machine guards are in place
   5. check that broaching tools are in a safe and usable condition
   6. hold components securely without distortion
   7. leave the work area and machine in a safe and appropriate condition on completion of the activities
2. Set up one of the following types of machine:
   1. horizontal broaching machine
   2. vertical broaching machine
3. Set up the workpiece and broach, to include all of the following:
   1. selecting and setting the appropriate work holding device
   2. locating and, where appropriate, securing the workpiece in the holding device
   3. fitting and aligning the appropriate broach
   4. aligning the workpiece in relationship to machine axis
4. Set up machine in accordance with instructions and specifications, to include setting all of the following:
   1. stroke position and length mechanisms
   2. cutting fluid flow rate
   3. machine guards/safety mechanisms
   4. stroke speed/feed
   5. broach pulling pressure
5. Set up the machine to produce internal and external profiles that include four 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
6. Machine components made from one type of material from the following:
   1. ferrous
   2. non-ferrous
   3. non-metallic
7. Set the machine to produce components within all of the following quality and accuracy standards, as applicable to the operations performed:
   1. dimensional tolerance equivalent to relevant standards
   2. surface finish 63 µin or 1.6µm
   3. components to be free from false tool cuts, burrs and sharp edges

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3026

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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Engineering; manufacturing; mechanical; setting; broaching machines; horizontal; vertical; work holding devices; mounting workpiece; selecting broaches

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