Federal Broach, part of the NIDEC Machine Tool Corporation in Ritto, Japan, alongside NIDEC OKK, PAMA and Takisawa, serves key industries like automotive, large truck manufacturing, aerospace, agriculture and defense. Spanning 96,000 sq. ft., its manufacturing facility specializes in producing broach machines, a variety of broach tools and the sharpening and recoating of gear-cutting tools. The company has its own coating facility, a rare feature among gear-cutting tool suppliers, highlighting its dedication to offering comprehensive solutions to customers.
To meet the escalating demand for gear-cutting tool services, Federal Broach recently augmented its capabilities by integrating a second coating system. This strategic enhancement positions the company to efficiently handle increased business volumes, providing crucial support to gear manufacturers across the United States.
A pivotal element in Federal Broach's enduring success and expansion has been its strategic collaboration with NUM, a provider of CNC control solutions. This partnership, which commenced in 1999 when Federal Broach embarked on upgrading its Brown & Sharpe spline grinder, has proven instrumental in modernizing its operations.
Ken Kernen, President of Federal Broach, recalls the early days, highlighting NUM's willingness to engage in a custom, one-off project. This collaboration laid the foundation for Federal Broach's standardized use of NUM for many of its broach production machines.
Kernen said: "NUM was willing to work with us. We had a custom, one-off project. None of the other approached CNC control suppliers were interested in a one-off custom job. Now we have standardized on using NUM for all our broach machine products." Reflecting on the partnership, Kernen emphasized the invaluable support provided by NUM's customer service team, which surpassed expectations during the initial project.
Federal Broach has consistently turned to NUM for various projects, leveraging NUM's flexible controls and drive systems, allowing it to tailor machine interfaces and functions for specific operations. This collaborative approach has significantly enhanced efficiency, maintained quality standards and prolonged the lifespan of Federal Broach's high-value machines.
In 2023, Federal Broach and NUM joined forces once again to introduce the 10T economical broach machine, marking a natural progression from their successful collaboration in broach tool production. Seeking a partner with a global presence, exceptional support infrastructure and a diverse product range to meet machine requirements across all lines, NIDEC chose NUM for this endeavor.
The broach machine process entails the precise interaction between the workpiece and the broach, a multitoothed cutting tool with progressively larger teeth or cutting edges. The broach is gradually fed into the workpiece at a controlled rate, while its teeth progressively remove material to form the desired shape or feature. Modern broaching machines, including the 10T economical broach machine, have transitioned from hydraulic systems to electric servo drives for enhanced precision and control.
The NUM Flexium+ CNC and MDLUX Servo drive system emerged as the ideal solution, providing a unified hardware and software platform that seamlessly integrates with base nonhelical models and extends to NIDEC's more complex dual ram and helical machines. This approach empowers OEMs to capitalize on application expertise, optimizing control engineering efficiency to deliver competitive machines. NUM's MDLUX motor/drive kits for the axes (known as the Loader, Handling and Ram) offer versatility in motion control, delivering the precision required and providing the power necessary for the broaching process.
The key advantages of the NUM CNC and drive system encompass precision, flexibility, energy efficiency, minimal maintenance requirements and enhanced control over the machining process. These attributes collectively contribute to improved productivity, operational efficiency and cost-effectiveness for Federal Broach and its customers.
"This state-of-the-art machine from Federal Broach, powered by NUM, demonstrates the seamless integration of cutting-edge technology and precision engineering," said a spokesperson. "The NUM Flexium+ 6 serves as the cornerstone, providing a robust platform for streamlined operations. Notable features, such as the Early Block Change function to begin executing movement of the next block before the current block has ended, a standardized PLC Control system, flexible EtherCAT IO and safety modules, and an enhanced operator experience facilitated by a 12-inch FS122 display running custom made visualization screens, all contribute to Federal Broach's commitment to providing machines that are efficient, high quality and high safety.
For more information contact:
Steve Schilling
NUM Corporation
603 East Diehl Road, Suite 115
Naperville, IL 60563
630-505-7722
sales.us@num.com
www.num.com
Federal Broach Holdings
1961 Sullivan Drive
Harrison, MI 48625
989-539-7420