Firstly, selecting the appropriate broach is the key to ensuring size accuracy. The geometric parameters, material, and heat treatment process of the broach will directly affect the processing accuracy. The design of the broach should be reasonably matched according to the material, shape, and precision requirements of the workpiece to be processed. The factors such as the helix rise, pitch, anterior angle, and posterior angle of the broach need to be calculated accurately to ensure uniform cutting of each tooth and avoid size deviation caused by uneven cutting force.



Secondly, the rigidity and stability of the machine tool have a direct impact on the size accuracy. The broaching machine should have sufficient rigidity to resist vibration and deformation during the cutting process, while ensuring the smooth operation of the broach. Regular maintenance and calibration of the machine tool to ensure the accuracy of the spindle movement, fixture positioning, and broach guiding accuracy are important means to control processing errors.



Thirdly, the clamping method of the workpiece must also be strictly controlled. During the broaching process, if the workpiece is not fixed securely or the positioning is not accurate, it is easy to produce offset or deformation, which will affect the final processing size. Therefore, high-precision fixtures should be used, and it should be ensured that the workpiece and the broach axis maintain good centrality. If necessary, auxiliary support structures can be used to reduce the vibration and deformation of the workpiece during the cutting process.



In addition, the role of the cooling and lubrication system in broaching processing cannot be ignored. Rational supply of cutting fluid can effectively reduce the cutting temperature, reduce thermal deformation, and thus improve the size stability. At the same time, good lubrication can reduce the friction between the broach and the workpiece, extend the life of the broach, and improve the surface quality and size accuracy of the processing.



Finally, the detection and adjustment during the processing process are also very important. In mass production, it is necessary to carry out regular random inspections on the processed parts, using high-precision measuring tools such as inside diameter micrometers and coordinate measuring machines for size detection. Once size deviations are found, it is necessary to adjust the broach parameters in time or replace the worn broach to prevent the production of mass scrap.



In summary, in the process of broaching, it is necessary to comprehensively improve the processing accuracy from multiple aspects such as broach selection, machine tool status, workpiece clamping, cooling and lubrication, and process detection. Only through scientific management and strict process control can we ensure that the parts produced by broaching meet the design requirements for size accuracy and satisfy the needs of modern manufacturing industry for high-quality parts.