ISSUE Machine is alarming / stalling POSSIBLE CAUSES Broach Holder is off-center Broach Holder bearings failing Excessive chip accumulation RECOMMENDATION Make sure the Adjustable Tool Holder is centered correctly. 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. 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

ISSUE Skid / witness marks on chamfer of workpiece POSSIBLE CAUSES Broach is bouncing off the face of the workpiece at initial contact RECOMMENDATION 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.

ISSUE Spiraling form / form is getting smaller towards bottom POSSIBLE CAUSES Excessive chip accumulation Broach Holder bearings failing RECOMMENDATION 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 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.

ISSUE Workpiece / stock is pushing back into the machine POSSIBLE CAUSES Workpiece not held tight Excess pressure is created by trapped fluids/air Excessive chip accumulation RECOMMENDATION Use a serrated collet to hold the workpiece. 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. 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

ISSUE Broach tool chipping / poor tool life POSSIBLE CAUSES Broach Holder is off-center Broach Holder bearings failing Improper workpiece preparation Speed is too high (RPM) RECOMMENDATION Make sure the Adjustable Tool Holder is centered correctly. 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. Check workpiece geometry: Refer to the part preparation guide (page 34-35) For Internal Broaches, increase pre-drill depth and size (larger I.D.) For External Broaches, pre-turn dia. smaller (smaller O.D.) Ensure there is a 45 lead-in chamfer (ideal) Consider broaching material in annealed state Refer to speeds and feeds chart.

ISSUE Form is larger than the broach POSSIBLE CAUSES Broach Holder bearings failing Too much end play in holder RECOMMENDATION 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. Measure holder end play. If end play is more than .005", replace the bearings. Bearing Rebuild Kits with instructions are available. Slater Tools offers inspection and repair services.

ISSUE Form not centered / teeth larger on one side POSSIBLE CAUSES Broach Holder is off-center Workpiece deflection RECOMMENDATION Make sure the Adjustable Tool Holder is centered correctly. Reduce speed during initial contact (maintain feed rate). Support the workpiece to ensure there is no deflection.

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