World First

A direct comparison of common manufacturing processes, using a groove as an example, illustrates the technological advantage: While static slotting via the machine spindle takes 60.6 seconds of active time (machine costs: €2.53) and milling with an angle head takes 30 seconds (costs: €1.25), BENZ’s driven broaching unit reduces the machining time to just 8 seconds per groove.

This corresponds to an impressive 87 percent savings in cycle time and machine costs, as well as a reduction in component costs to just €0.33 per groove.

The key feature of this technology is that the entire kinematics of the cutting process are self-contained within the broaching unit. An eccentric converts the rotational motion of the drive shaft directly into linear motion within the unit, which reduces wear on the machine. There is no need to move heavy machine components or axes for material removal. This protects the machine’s guideways from premature wear. After the broaching operation, the cutting edge automatically lifts off, which prevents the tool from breaking off during retraction and significantly extends the machine’s service life.

From the Lathe to the Machining Center: A Success Story

The success story of the broaching concept began back in 2009 with a compact broaching unit for turning centers, the current version of which comes standard with a robust oil-bath lubrication system. After successfully completing several thousand customer projects, BENZ Tooling applied this proven design principle to other machine types, including multi-spindle automatic lathes, and is now focusing intensively on machining centers.

A compact design, consisting of an attachment head with a one-piece housing combined with a torque support and machine connection, ensures the necessary rigidity and brings together comprehensive expertise in broaching systems and machining centers for modern complete machining in a single setup.

From a technical standpoint, the current version of the LinA 4.0 axial broaching unit for machining centers impresses with its strong performance specifications: It can cut grooves with diameters of up to 12 millimeters. The usable cutting stroke is 32 mm at up to 1,500 double strokes per minute – with a feed rate of up to one-tenth of a millimeter (0.1 mm).

For components that require deeper profiles, BENZ will gradually expand its product family of broaching units for machining centers.