Precision Shaft Tooth Broaching Machines for Industrial Use

• Customization: Available
• After-sales Service: Provide
• Warranty: 1 Year
• Model NO.: ZG50XX
• Application: Metal
• Process Usage: Metal-Cutting CNC Machine Tools
• Movement Method: Contour Control
• Control Method: Closed-Loop Control
• Numerical Control: CNC/MNC
• Processing Precision: 0.03~0.04(mm)
• Performance Classification: High-End CNC Machine Tools
• Certification: CE, ISO 9001
• Condition: New
• Transport Package: Standard Export Package
• Trademark: UBRIGHT
• Origin: Cn
• HS Code: 8461300000
• Production Capacity: 100 Set

Product Description

Machine Introduction

The special broaching machine for shaft gears is a precision broaching device designed for processing key transmission surfaces of shaft gears (integrated parts of shafts and gears), targeting structures such as internal teeth, internal splines, and internal tooth grooves of shaft gears. It serves as the core special equipment for batch production of shaft gears.

 

Core Advantages

 

1. Self-developed Anti-overturning Fixture: Three-point positioning + symmetrical clamping offsets large cutting force during broaching for stable processing.
2. Dual-piece Synchronous Broaching: Boosts productivity by 250% with a cycle time of 4 minutes for two pieces.
3. High-precision Linear Guide Rail: Broaching tool movement error ≤ 0.005mm, ensuring tooth groove precision ≤ 0.01mm.
4. Quick Model Changeover System: Fixture/tool replacement within ≤ 25 minutes to flexibly meet multi-variety orders.
5. Closed-loop Online Inspection: Real-time quality monitoring with automatic rejection of non-conforming products.

 

It is suitable for batch processing of shaft gears in construction machinery, agricultural machinery and other fields, helping customers improve quality, enhance efficiency, reduce costs and increase profits.

 

 

 

Workpiece Basics

Shaft gears are key components for driving drill pipes and leveling masts of rotary drilling rigs. They must withstand high-intensity impact loads and are commonly made of 40CrMnMo alloy steel. Geometrically, they feature consistent tooth groove depth and symmetrical tooth profile. However, the large cutting force during broaching tends to cause overturning displacement, leading to precision deviation. Common risks include part scrapping due to overturning, inconsistent tooth groove precision, and order delays caused by long model changeover time.

 

Core Pain Points

Traditional broaching machines process one piece at a time with a cycle time of 3 minutes per piece, achieving a daily output of only 100 pieces, which cannot meet batch production demands. Ordinary fixtures cannot offset cutting force, resulting in a scrap rate as high as 8%. Model changeover takes more than 1 hour, causing severe productivity loss. These pain points lead to: order delays (losing 2-3 customers monthly), increased costs (scrap + manual adjustment), and unstable quality (15% rise in complaint rate).

 

Technological Process

 

Blank (forging) → Rough Machining (external cylindrical milling) → Broaching (core process of ZG50XX: double-piece clamping → tooth groove broaching → online inspection) → Surface Treatment (deburring) → Finished Product Packaging.

 
 

Key Points by Segment

  

• Broaching Stage: Self-developed special fixture for shaft gears (three-point positioning + symmetrical clamping) offsets overturning torque; dual-station synchronous broaching with a cycle time of 4 minutes for two pieces; high-precision linear guide rail (error ≤ 0.005mm) ensures tooth groove accuracy.
• Inspection Stage: Online dimension measuring instrument monitors tooth groove depth and tooth profile in real time, with automatic rejection of non-conforming products.

 
 

Revenue Data

 

• Efficiency: Daily output increased from 100 pieces to 250 pieces (+250%).
• Precision: Tooth groove tolerance ≤ 0.01mm, tooth profile accuracy meets Grade 5 of GB/T 10095.1-2008.
• Cost: Scrap rate reduced from 8% to 0.5%, saving 80,000 yuan monthly; model changeover time ≤ 25 minutes, cutting productivity loss by 70%.
• Tool Life: Coated broaching tools extended service life by 15%.

 

Customer Cases

 

After introducing ZG50XX, a construction machinery factory achieved a 250% increase in the productivity of rotary drilling rig rack gears, reduced the scrap rate to 0.5%, and cut costs by 120,000 yuan monthly.

 

Application Scenarios: Batch processing of shaft gears for rotary drilling rigs, agricultural machinery, and automation equipment.

 

Parameters and Configuration

 

Parameter Name	Value
Rated Pulling Force	50kN
Rated Working Stroke	800mm
Broaching Speed	2~10m/min (Stepless Speed Regulation)
Main Slide Return Speed	2~20m/min (Stepless Speed Regulation)
Maximum Workpiece Outer Diameter	Φ500mm
Main Motor Power	7.5kW
Machine Tool Dimensions (Length×Width×Height)	2300×2550×3000mm
Quick Model Change Time	≤25 minutes

Configuration Name	Details
Core Fixture	Self-developed gear-type anti-overturning fixture (Patented)
Broaching Station	Dual-part synchronous broaching design
Guidance System	High-precision linear guide (Error ≤0.005mm)
Control System	PLC programmable (Parameter storage)
Detection Device	In-line dimension measuring instrument
Model Change System	Quick fixture/tool change mechanism
Broaching Tool	Custom coated high-speed steel broaching tool
Safety Protection	Fully enclosed protective cover + Emergency stop