Custom Push Type Broach Tool Bars

Custom push type broach tool bars are frequently asked of our clients to fit the needs of their application. We have always offered special grind inserts to fit our In Stock Broach Tool bars to accommodate those special jobs. But we now offer custom, “one-off” broach tool bars.

There are many options we at CNC Broach Tools consider before we can generate a quote for custom broach tool bars.

  • Is your application high volume? If you only have a couple of one-off parts on a job that is not re-occurring, the special grind inserts option will be your fastest and cheapest path forward, or our tooling just might not be a best fit. If you are going into production and have numerous part runs per year you may want special broach tool bars. We do require a minimum of 2 special broach tool bars per order.
  • What is the time frame of your job? Common lead times are 3-4 weeks. If your job is required in a couple days we unfortunately can not help with custom tooling and the special insert grind option is best. In that scenario Modification to the tool might be necessary as well as special grinds on our indexable inserts.
  • What is the most important information CNC Broach Tools needs? Help us, help you. The most important information needed is your bore size, keyway width, length of cut, and depth of cut radially. But also time-frame, volume and repeatability of the job factor into our recommendations for special “one-off” CNC broaching tool bars.

Cost of custom push type broach tools vary from application. We pride ourselves on creating cost effective, Made in America broach tooling for your applications.

CNC Push-Type Broaching Cycle Time Calculator

Short of time, extra hands, and brain cells trying to figure out a new keyway broach application? Calculate CNC push-type broaching process cycle time on a mill or lathe. To broach keyways on a CNC lathe or mill, CNC Dirt makes understanding broach process time easier! What started out as a simple app has now made moves to replace the machinist handbook entirely.

Push-Type Broach Keyway Calculator
  • Calculate cycle time when push-broaching in a CNC Mill or Lathe.
  • App calculates cut time based on keyway depth, length, & depth of cut.
  • Visit CNCDirt.com for more details

Single Point Broaching Speeds and Feeds

“These are general single point broaching speeds and feeds guidelines for CNC Broaching based off of actual client testimonials”

Below are speeds and feeds recommended by CNC Broach Tools. Our long term clients have also contributed for automated broaching with carbide, not HSS. CNC Broach Tools use our proprietary TiN coated carbide inserts with two cutting edges.

The patented CNC Broach Tool™ system was originally sold through Razorform Tools for the single point broaching process. This Modern Machine Shop article, called “The Future of Broaching” from September 2007: http://www.mmsonline.com/articles/the-future-of-broaching. This is a case study of how our product performed at Baldor Electric Motors (now ABB) on their 4140 motor shafts.

The CNC Broach Tools speeds/feeds chart is a compilation of knowledge and client feedback dating back to 2006 and Razorform Broaching Tools. Here is a more recent video from Baldor showing how we got our .0006” per pass for 56Rc 4140:   https://youtu.be/D0HbWEq4d2c

For a Client Testimonial on 304 Stainless Click the Blog Post Below:

Single Point Broaching Speed/Feed Chart
CNC Broach Tool LLC

www.cncbroachtools.com

Keyseat Cutters for Blind Keyway

CNC Keyseat Broaching Duotec Testimonial

CNC Broach Tool Keyseat Cutters do not go past 5/8 in width tolerance. When Dan Harvey from Duotec Tool in Maple Grove, MN had a 1” wide key slot to cut. We told him that we could not provide broach tooling for his keyway application. Our T58L broach tool could fit his bore, and get his 7” Length of Stroke. We did not offer tooling for the broached key seat width dimension of 1”.
I asked Dan what the depth of his application was and he told me again that it was 7”. I explained that the 7” was his Axial Depth but I needed to know his Radial Depth so that I could offer a potential solution. We discovered that his Depth Radial was a very shallow .070” so I suggested that he take our T58L Broach Tool  and “step it over”. The N58 keyway broach insert for that broach tool has a .338” Depth Radial capability so Dan could create the wider keyseat for his 1” width keyway by cutting two keyways side-by-side.
The ability for CNC Broach Tools to offer the “step it over” solution is limited by Depth Radial of an application. To understand the Depth Radial Broach Dimension visit this blog post “The Forgotten Keyway Broach Dimension”.
Dan had a very limited amount of groove relief at the end of his keyway. We believe because of the shallow radial depth the process was a success.
Here’s Dan’s testimonial. “This blind keyway has no thru-relief, nearly no  groove relief where the keyway stops. It is 1” wide and nearly 7” long. The broach tool (and guidance) from CNC Broach Tool worked amazingly well! Thanks for helping make our project a success!”

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Finding Centerline for CNC Broaching Tool System

Correct Centerline Prevents Crashes During the Broaching Process

The downloadable broach tool prints here:  Broach Tool Centerline For Programming   are for all eleven standard keyway slotting tool sizes and have the dimension from the centerline of our broach tool to the top of the keyway broach insert. If you do not take the time to find the center you may crash. As you could be taking to much of a cut for your radial depth.

Also see the picture below: when the set screws press our keyway broach insert up against the right wall of the Broach tool pocket that action locates the insert on center. The right wall is on center of the broach tool.

You still must take the time to “indicate squareness to the part” as depicted here under “Set-Up”: Keyway Cutters Speed Feed

Finding the Centerline

 

The Forgotten Keyway Broach Dimension

Understanding the Depth Radial Keyway Dimension

The Forgotten Keyway Broach Dimension: A keyway, internal or external, has three dimensions. However, when going over applications with clients for Internal Keyways CNC Broach Tools needs clients to provide us with four dimensions. Not the drawing, just four dimensions. They are:

1) The Width of the keyway and the specific width tolerance needed
2) The Bore size that the tool and insert must fit into
3)  The Length of Stroke needed. Most refer to this as the Depth. Specifically it is the Axial Depth of the application.
4) and the forgotten keyway dimension, which is the Depth Radial Dimension
Historically, the standard for the Depth Radial keyway dimension is half the width of the keyway.
 

Example: a 3/16 width keyway typically should have a .090” – .100” Depth Radial Dimension

CNC Broach Tools coined a new machining vocabulary term calling the Depth Radial the Height of the Groove to differentiate it by terminology from the Depth Axially. Most of the clients that call give us the Length of Stroke Depth, or Axial Depth, instead of the Depth Radially when we ask for the Depth. Even when we ask for the Depth Radially they keep giving us the Depth Axially.  It gets very frustrating for both parties when there are two “depths”. We try to explain that it’s not possible for the Depth Radial to be 2” and that that’s the Depth Axially! or the Length of Stroke! We have had to educate thousands of clients on the meaning and importance of the Depth Radial Dimension.
Making the situation more frustrating is that I’ve never seen a drawing with the Depth Radially called out specifically. Sometimes, you’ll have a Bore size and then another bore dimension to the “top” of the keyway. Other times it’s from the centerline of the bore and you have to divide it by two. It’s odd to us that this is not a standardized dimension and procedure.
We call the Depth Radially the forgotten Keyway Broach dimension because very rarely do clients know what we are talking about when we ask for it. Engineers with decades of experience need the dimension explained to them. But more important than the engineer is that the machinists and operators know what the Depth Radial dimension is and that on a CNC Broach Tool the capability to cut it is a Finite Dimension!

Example: the depth radial capability of our 3/8 internal keyway insert is .200” meant for a standard internal keyway. I had a first time user call saying the insert had ripped out of the pocket of the tool. After reviewing everything I remembered to ask what his Depth Radial was and he said his application needed  .220”. He crashed because he did not think of this dimension and that how high our insert sticks up above the tool with clearance to cut is a Finite amount. 

Understanding why the Depth Radial is important is because some jobs are NOT standard and need a deeper Depth Radial than our standard insert will do. We can special grind the widths of larger inserts that have more Depth Radial Capability, but that larger tool and insert must fit your bore size.
I see a gap in education here both on the machining and engineering side. Many engineers do not seem to grasp as they design that the standard Depth Radial for a internal keyway is half the width. They’ll arbitrarily make the Depth Radial more than it needs to be not understanding the issue with tooling this creates for the manufactures of their parts. Most cutting tool companies make standard tooling product lines for standard dimensions. When an engineer does a random dimension not in line with standard procedure expensive special tooling, one-offs, must be made costing more money and increasing lead times. For the broaching process in particular this “goof-up” is hard because the higher or farther an insert sticks up above the tool to cut the slot the more tool bar meat you need to support it.
 

Meaning if you have more depth radially you need a bigger bore to fit into because you need a larger tool body. 

A broach insert for an internal keyway that sticks way high up above the broach tool and a large thick tool body and a small bore to fit, you just can’t make it all work. As they design engineers need to keep in mind that geometrically there are physical constraints on inserted broach tools, so we encourage them to make the Depth Radial standard.
Finally, you can use our broach tool and “step it over” to do wider keyways, but remember this possibility is limited by the Depth Radial capability.

 

Keyway Broach Dimension

Keyway Broach Dimension

Keyway Broach Tools Size Chart

Lathe Broaching 4140 Internal Keyway

Broaching 4140 with Razorform CNC Broach Tools

To read a Modern Machine Shop article about CNC Broach Tools Lathe broaching 4140 internal keyway at 56Rc on Okuma Cadet Lathes at OEM electric motor manufacturer Baldor Electric Motors click here:  http://www.mmsonline.com/articles/the-future-of-broaching
This article titled, “The Future of Broaching”, is from September 2007 when our broach tools were sold through a different company called Razorform Tools. Which indicates just how long this proprietary, inserted broaching system has been successful for our clients. We frequently get Razorform Broach Tool clients asking if the old broach tools and keyway inserts are interchangeable. The answer is Yes!
We also get calls from concerned 1st time users concerned about wear on their lathes from broaching. Hopefully this article eases fears as we would not be in business if the broaching process damaged our clients lathes. As you can see this broach tool system for lathes has been around for more than a decade!

Lathe Broaching 4140 Internal Keyway

Broaching with Razorform CNC Broach Tools

Okuma Lathe Broaching Programming Template

 

Blind Keyway Broaching Monel Interrupted Cut

Blind Broaching Monel

Thank you Karl for your testimonial on blind keyway broaching monel interrupted cut!

We recently ran up against a tough lot of Monel sockets requiring slotting six places through a helix. The material was far harder than usual, and our usual rotary broach couldn’t handle it. Because the run was short, we couldn’t spend a lot on tooling. The CNC Broach Tool Company tool cut the nasty stuff beautifully, even though the interrupts, and got the job done with less burring and deformation. Even managed to salvage the part that the old broach broke down on. Good job! Thanks for the help.

Karl Mech
Hydrasearch Co
Stevensville, MD

Blind Keyway Broaching Monel Interrupted Cut

Blind Keyway Broaching Monel Interrupted Cut

CNC Broach Tools Blog

 

Blind Keyway Broaching for CNC Lathe

Monty Twingstrom Testimonial

Thank you Monty Twingstrom for your testimonial on blind keyway broaching for your CNC Lathe!

We currently implemented a broach tool from CNC Broach Tool Company, it was a broach application that was not a through hole which required us to look into farming out this application. With implementing the CNC Broach Tool Company tool we were able to not only keep this operation in-house, we were able to combine it to the lathe operation and also because of that we were able to add the drill and tap cross holes to make it complete in one operation which is always a cost saving if you don’t have to handle the parts more than once. Centerline held really well because the bore and the broached keyway were done in the same operation.

Monty Twingstrom
CNC Manager
K-Manufacturing, Inc.
Osseo, MN

Blind Keyway Broaching

Blind Keyway Broaching on CNC Lathe

CNC Broach Tools Blog

Tormach Mill Broaching Program Template

Tormach Mill Broaching Program Template

CNC Broach Tool contracted out the broaching templates we offer and that is exactly what they are, a guide to build from for those interested in broaching on their Tormach Lathe or Mill. 
 
We do not provide ongoing programming support or details for your specific application
      
We are not programmers and do not have one on staff
 
The reason for this is we could never get you the right answer anyway as we can never know which of the many coding options you have or have not purchased with your machine. Every year Tormach updates and changes their controls
 
The foundational information you find here is all we can provide for you. If you are struggling with programming you need to reach out to the company that sold you the machine to see what options you have purchased and see if Tormach has tweaked code or if you need to add an option.

CNC Broach Tools offers a free Tormach Mill Broaching Program template. If you want to broach your keyways or splines CNC Broach Tools can help!

Click to download PDF >> CNC BROACH TORMACH MILL

Click to download .NC >>  TORMACH MILL G CODE BROACH.NC

Tormach Mill Broaching Program

Mill Broaching Blind Keyway

  • Please do not ask CNC Broach to program your machine for the keyway slotting application.
  • We can never know the different CNC program options purchased with your lathe or mill. Please reach out to your Haas dealer and find out what CNC programming options you purchased with your lathe or mill.
  • CNC Lathe and Mill manufacturers come out with updated controls frequently. Things may have changed since this CNC Broach Template.
  • The CNC broach program templates are a guide or foundation for the user to tailor to their specific application.
  • There is more advanced CNC Keyway Slotting program information in our Keys to Programming CNC Broach Tools guide.

“The Only Inserted CNC Broaching System Manufactured in the USA”

Please feel free to leave a comment below to better help improve our templates to help you!

http://www.cncbroachtools.com

DISCLAIMER: This CNC Broach Tool Program Template is for informational and reference purposes only. It is provided without guarantees or warranty. CNC Broach Tool LLC makes no warranties of any kind, either express or implied, including but not limited to warranties of merchantability, fitness for a particular purpose, of title, or of non infringement of third party rights. Use of this programming template by a user is solely and completely at the user’s risk.