During production, broach teeth gradually lose sharpness due to:
abrasion from hardened materials
built-up edge formation
heat and micro-chipping
improper lubrication
If a worn broach is used:
cutting forces increase
machine load rises
size goes out of tolerance
surface finish deteriorates
broach may break (very costly)
A Broach can often be re-sharpened 15–30 times depending on its design. Since broaches are expensive precision tools, re-sharpening significantly reduces tooling cost per component.
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