broaching machine repairer Interview Questions and Answers

1. What is a broaching machine?

   • Answer: A broaching machine is a machine tool that uses a multi-toothed cutting tool, called a broach, to remove material from a workpiece in a single pass. This creates internal (internal broaching) or external (external broaching) features with high accuracy and surface finish.

2. Describe the different types of broaching machines.

   • Answer: Common types include horizontal, vertical, and surface broaching machines. Horizontal machines are best for long, slender parts; vertical machines for shorter, heavier parts; and surface broaching machines for surface machining operations.

3. Explain the broaching process.

   • Answer: The broach, with progressively larger teeth, is pulled or pushed over the workpiece. Each tooth removes a small amount of material, gradually shaping the workpiece to the final dimensions. The process is typically fast and efficient.

4. What are the common problems encountered in broaching machines?

   • Answer: Common problems include broach breakage, workpiece breakage, poor surface finish, dimensional inaccuracies, improper lubrication, and hydraulic or electrical system malfunctions.

5. How do you troubleshoot a broach that is breaking frequently?

   • Answer: Check for excessive cutting forces (due to improper setup, dull broach, or hard material), incorrect broach speed or feed, improper lubrication, workpiece clamping issues, and potential defects in the broach itself. Inspect the broach for wear and tear.

6. How do you diagnose and repair a hydraulic leak in a broaching machine?

   • Answer: Identify the leak source, inspect hydraulic lines and fittings for damage, replace damaged seals or O-rings, check the hydraulic pump and reservoir for leaks, and potentially bleed the system after repairs.

7. Explain the importance of proper lubrication in broaching.

   • Answer: Proper lubrication reduces friction, heat, and wear on the broach and workpiece, improving surface finish, extending broach life, and preventing damage to the machine.

8. How do you ensure the accuracy of the broached parts?

   • Answer: Accurate setup, proper machine calibration, sharp broaches, consistent cutting parameters (speed, feed), rigid machine structure, and regular maintenance contribute to accurate broaching.

9. What safety precautions should be taken when working with a broaching machine?

   • Answer: Always wear appropriate safety gear (eye protection, hearing protection, gloves), ensure proper machine guarding is in place, never reach into the machine while it's operating, follow lockout/tagout procedures during maintenance, and be aware of potential hazards like sharp edges and moving parts.

10. How do you perform routine maintenance on a broaching machine?

    • Answer: Routine maintenance includes checking and lubricating moving parts, inspecting hydraulic fluid levels and condition, checking electrical connections, cleaning debris, inspecting the broach for wear, and verifying machine accuracy.

11. What is the difference between a pull-type and push-type broaching machine?

    • Answer: A pull-type broaching machine uses a power mechanism to pull the broach through the workpiece, while a push-type machine pushes the broach through. Pull-type machines are generally preferred for heavier cuts and longer broaches.

12. How do you sharpen a broach?

    • Answer: Broach sharpening is a specialized process usually done by a professional. It involves precision grinding to restore the cutting edges of the teeth to their original profile and sharpness. Improper sharpening can ruin a broach.

13. What are the different types of broach materials?

    • Answer: Broaches can be made from high-speed steel (HSS), carbide, or even ceramic materials, depending on the material being broached and the required production volume.

14. Describe the process of setting up a broaching machine for a new job.

    • Answer: This involves selecting the appropriate broach, setting the correct speed and feed, securely clamping the workpiece, ensuring proper alignment of the broach and workpiece, and performing a test run before full production.

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