40
TROUBLESHOOTING SOLUTIONS
ISSUE POSSIBLE CAUSES
RECOMMENDATIONS
Machine is
alarming /
stalling
Skid / witness
marks on
chamfer of
workpiece
Spiraling form /
form is getting
smaller towards
bottom
Workpiece
/ stock is
pushing
back into the
machine
1. Broach Holder is off-center
2. Broach Holder bearings failing
3. Excessive chip accumulation
1. Broach is bouncing off the
face of the workpiece at
initial contact
1. Excessive chip accumulation
2. Broach Holder bearings failing
1. Workpiece not held tight
2. Excess pressure is created
by trapped fluids/air
3. Excessive chip accumulation
1. Make sure the Adjustable Tool Holder is centered correctly
(see page 38, or view videos at
).
2. Check the Broach Holder bearings by turning the spindle
in your fingers. The spindle should spin freely. If you
feel hesitations, graininess, or stickiness, replace the holder
bearings. Bearing Rebuild Kits with instructions are available.
Slater Tools offers inspection and repair services.
3. Typical solutions to reduce chip accumulation:
• For Internal Broaches, increase pre-drill size (larger
workpiece I.D.)
• For External Broaches, pre-turn dia. smaller (smaller
workpiece O.D.)
• Reduce depth of broached area (less than 1.5 x Minor Dia.)
• Add an undercut or recess to help break the chip
1. Reduce the speed to approx. 100-200 RPM during initial
contact into the chamfer (maintaining feed rate). Then,
increase the speed back to the recommended RPMs once
tool is .010” into the chamfer. Consider leaving extra stock
on workpiece and clean-off after broaching.
1. Typical solutions to reduce chip accumulation:
• For Internal Broaches, increase pre-drill size (larger
workpiece I.D.)
• For External Broaches, pre-turn dia. smaller (smaller
workpiece O.D.)
• Reduce depth of broached area (less than 1.5 x Minor Dia.)
• Add an undercut or recess to help break the chip
2. Check the Broach Holder bearings by turning the spindle
in your fingers. The spindle should spin freely. If you
feel hesitations, graininess, or stickiness, replace the holder
bearings. Bearing Rebuild Kits with instructions are available.
Slater Tools offers inspection and repair services.
1. Use a serrated collet to hold the workpiece.
2. Typical solutions for releasing trapped fluids/air:
• Turn off coolant during broach cycle
• Increase the pre-drill hole size (increase I.D.)
• Use a vented broach. Slater Tools offers vented broach
options.
3. Typical solutions to reduce chip accumulation:
• For Internal Broaches, increase pre-drill size (larger
workpiece I.D.)
• For External Broaches, pre-turn dia. smaller (smaller
workpiece O.D.)
• Reduce depth of broached area (less than 1.5 x Minor Dia.)
• Add an undercut or recess to help break the chip
If you have any technical questions or concerns, Slater Tools’ experienced associates and
engineers are readily available to assist you. Please call or visit our online Customer Support &
Service section and instructional videos at
.
TECHNICAL SUPPORT
•
EMAIL:
