Broaching of Aluminum Automotive Engine Components

This paper presents evidence that aluminum automotive engine components such as cylinder heads and crankcases can be broached on the same type of large horizontal broaches that have been traditionally used to broach cast iron engine components. The evidence presented consists primarily of results from extensive single tooth cutting tests. Recommendations are made regarding the proper tool material, tool geometry, cutting fluid, and tool layout for the successful broaching of typical hard and soft automotive aluminum alloys.