A method for manufacturing a rack including a toothing with variable pitch includes a roughing step, in which a blank of the rack is produced, the blank including at least one extra thickness on at least one zone of the toothing compared to a desired dimensional feature of the rack. The method also includes a finishing step, in which the at least one extra thickness of the blank is removed.

A broaching unit for rules of die cutters which comprises a supporting structure, for example a frame, a guide of a die cutter rule, and a tool-holding arm equipped with at least one broaching tool is described. The guide defines a sliding surface on which the rule is fed intermittently. The tool-holding arm is mounted on the supporting structure and is susceptible to reciprocating movements with respect to it and with respect to the guide, preferably forward and backwards movements along a transversal direction of the rule, just to intercept the die cutter rule with the broaching tool when the rule is stopped. Advantageously, the tool-holding arm is equipped with at least two broaching tools, for example four tools, and can be oriented with respect to the guide, for example can rotate on itself, to selectively activate one of the broaching tools, i.e. to bring one of the tools into contact with the rule.

A broaching unit for rules of die cutters which comprises a supporting structure, for example a frame, a guide of a die cutter rule, and a tool-holding arm equipped with at least one broaching tool is described. The guide defines a sliding surface on which the rule is fed intermittently. The tool-holding arm is mounted on the supporting structure and is susceptible to reciprocating movements with respect to it and with respect to the guide, preferably forward and backwards movements along a transversal direction of the rule, just to intercept the die cutter rule with the broaching tool when the rule is stopped. Advantageously, the tool-holding arm is equipped with at least two broaching tools, for example four tools, and can be oriented with respect to the guide, for example can rotate on itself, to selectively activate one of the broaching tools, i.e. to bring one of the tools into contact with the rule.

A broaching unit for rules of die cutters which comprises a supporting structure, for example a frame, a guide of a die cutter rule, and a tool-holding arm equipped with at least one broaching tool is described. The guide defines a sliding surface on which the rule is fed intermittently. The tool-holding arm is mounted on the supporting structure and is susceptible to reciprocating movements with respect to it and with respect to the guide, preferably forward and backwards movements along a transversal direction of the rule, just to intercept the die cutter rule with the broaching tool when the rule is stopped. Advantageously, the tool-holding arm is equipped with at least two broaching tools, for example four tools, and can be oriented with respect to the guide, for example can rotate on itself, to selectively activate one of the broaching tools, i.e. to bring one of the tools into contact with the rule.

A broaching unit for rules of die cutters which comprises a supporting structure, for example a frame, a guide of a die cutter rule, and a tool-holding arm equipped with at least one broaching tool is described. The guide defines a sliding surface on which the rule is fed intermittently. The tool-holding arm is mounted on the supporting structure and is susceptible to reciprocating movements with respect to it and with respect to the guide, preferably forward and backwards movements along a transversal direction of the rule, just to intercept the die cutter rule with the broaching tool when the rule is stopped. Advantageously, the tool-holding arm is equipped with at least two broaching tools, for example four tools, and can be oriented with respect to the guide, for example can rotate on itself, to selectively activate one of the broaching tools, i.e. to bring one of the tools into contact with the rule.

Stepped rotary broaches, and systems and methods employing such broaches, are disclosed herein. In one example embodiment, a stepped rotary broach includes a contact portion integrally formed with or coupled to a support portion. The contact portion includes a face and a periphery. The periphery includes an outer surface and a plurality of step formations, where each of the step formations extends between the face and a respective location along the periphery at which the respective step formation adjoins a respective portion of the outer surface. Each of the step formations includes a respective step including a respective surface region extending in a respective direction about a central axis of the stepped rotary broach. The respective surface regions of the respective steps are respectively positioned more closely to the central axis than are the respective portions of the respective outer surface that respectively adjoin the respective step formations.

Stepped rotary broaches, and systems and methods employing such broaches, are disclosed herein. In one example embodiment, a stepped rotary broach includes a contact portion integrally formed with or coupled to a support portion. The contact portion includes a face and a periphery. The periphery includes an outer surface and a plurality of step formations, where each of the step formations extends between the face and a respective location along the periphery at which the respective step formation adjoins a respective portion of the outer surface. Each of the step formations includes a respective step including a respective surface region extending in a respective direction about a central axis of the stepped rotary broach. The respective surface regions of the respective steps are respectively positioned more closely to the central axis than are the respective portions of the respective outer surface that respectively adjoin the respective step formations.