Profile sharpened type broaches are sharpened or re-sharpened by grinding at flank surfaces. These cutters have simple geometry with same rake and clearance angles all over cutting edge. These broaches are generally designed and used for machining flat surfaces or circular holes.

Cutting time is calculated by formula,
CT = W/ (N_s*F_c) where, W is width of work piece
N_s is bull wheel rpm
F_c is feed rate

Therefore,
CT = 1000/ (150*2)
= 3.34 min = 200 sec.

Machining by broaching is preferably used for making straight through holes of various forms and sizes of section, internal and external through straight or helical slots or grooves, external surfaces of different shapes, teeth of external and internal splines and small spur gears.

Face milled gears have no slot width taper but a large thickness taper, on or hand, face hobbed gears have an equal slot width and tooth thickness taper. Therefore, it is impossible to grind face hobbed gears using a cup-shaped grinding wheel.

The gear hob is a formed tooth milling cutter with helical teeth arranged like thread on a screw. These teeth are fluted to produce required cutting edges.

In shaping, attaining full depth requires a number of strokes to remove material in thin layers step-by-step by gradually infeeding single point tool. Whereas, broaching enables remove whole material in just a single stroke by gradually rising teeth of cutter called broach. Some are advantages of shaping process and surfaces with obstruction cannot be machined by broaching.

In this type of shaper, metal is removed when ram and thus tool moves towards column of machine, i.e. draw workpiece towards machine. The ram is generally supported by an overhead arm which ensures rigidity and eliminates deflection of tool.

The difference in outer and inner circumference of generating gear causes an extreme tooth thickness taper that leads to uneven tooth profile.

The angle between hob?s spindle axis and worpiece?s spindle axis varies depending upon type of product being manufactured.

There are total four indexing methods as listed below?
1) Direct indexing 2) Simple indexing 3) Compound indexing 4) Differential indexing.