Slater Tools: Number one for Rotary Branding

Troubleshooting Solutions

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.

ISSUE POSSIBLE CAUSES RECOMMENDATIONS
Machine is alarming / stalling

1. Broach Holder is off-center

2. Broach Holder bearings failing

3. Excessive chip accumulation

1. Make sure the Adjustable Tool Holder is centered correctly.

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
Skid / witness marks on chamfer of workpiece

1. Broach is bouncing off the face of the workpiece at initial contact

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.

Spiraling form / form is getting smaller towards bottom

1. Excessive chip accumulation

2. Broach Holder bearings failing

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.

Workpiece / stock is pushing back into the machine

1. Workpiece not held tight

2. Excess pressure is created by trapped fluids/air

3. Excessive chip accumulation

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
Broach tool chipping / poor tool life

1. Broach Holder is off-center

2. Broach Holder bearings failing

3. Improper workpiece preparation

4. Speed is too high (RPM)

1. Make sure the Adjustable Tool Holder is centered correctly.

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. 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 45lead-in chamfer (ideal)
  • Consider broaching material in annealed state

4. Refer to speeds and feeds chart.

Form is larger than the broach

1. Broach Holder bearings failing

2. Too much end play in holder

1. 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.

2. 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.

Form not centered / teeth larger on one side

1. Broach Holder is off-center

2. Workpiece deflection

1. Make sure the Adjustable Tool Holder is centered correctly.

2. Reduce speed during initial contact (maintain feed rate). Support the workpiece to ensure there is no deflection.