keyway broach set Factory

A keyway broach set is a collection of tools designed to cut keyways, which are slots or grooves in a bore or hub, allowing a key to secure a shaft. These sets are essential for creating precise fittings between rotating parts, commonly used in gears, pulleys, and other mechanical components. Understanding the different types of broaches, selecting the right set, and mastering the cutting process are vital for achieving accurate and reliable results.

Understanding Keyway Broaches and Sets

What is a Keyway Broach?

A keyway broach is a specialized cutting tool with a series of progressively larger teeth designed to remove material in a controlled manner. Each tooth cuts a small amount of material, gradually forming the keyway to the desired dimensions. Broaches are typically made of high-speed steel (HSS) or carbide for durability and cutting performance.

Components of a Keyway Broach Set

A typical keyway broach set includes:

Broaches: A series of broaches with varying tooth sizes, each used to deepen the keyway in successive passes.
Shims (or Bushings): Used to center and guide the broach in the bore, ensuring accurate keyway alignment.
Collared Bushings: Some sets include collared bushings which are used to align the broach and help with deeper cuts.

Types of Keyway Broaches

Keyway broaches are generally classified by their cutting method and geometry:

Push Broaches: Designed to be pushed through the workpiece using an arbor press or similar equipment. These are common in keyway broach set because of their relative ease of use and lower cost.
Pull Broaches: Designed to be pulled through the workpiece using a broaching machine. Typically for larger keyways and higher production volumes.
Rotary Broaches: Used in lathes or milling machines to create keyways. They are more complex and require specialized equipment.

Choosing the Right Keyway Broach Set

Factors to Consider

Selecting the appropriate keyway broach set depends on several factors:

Keyway Size: The width and depth of the keyway you need to cut. Broach sets are typically categorized by the range of keyway sizes they can produce.
Bore Size: The internal diameter of the part where the keyway will be cut. Bushings or shims in the set must match the bore size.
Material: The type of material being machined (e.g., steel, aluminum, brass). HSS broaches are suitable for most materials, while carbide broaches are better for harder materials.
Tolerance: The required precision of the keyway. High-quality broaches and proper technique are essential for achieving tight tolerances.
Budget: Keyway broach set prices can range widely, from affordable sets for occasional use to high-end sets for professional machining.

Popular Keyway Broach Set Options

Here are some popular keyway broach set manufacturers and their offerings:

Dumont: Known for high-quality broaches and complete sets suitable for various keyway sizes.
Guhring: Offers precision broaches and sets designed for demanding applications.
HHIP: Provides a range of affordable broach sets for hobbyists and small machine shops.
Wayleading Tools: Offers a range of quality broach sets. Visit Wayleading Tools for details. We specialize in providing durable and precise tools, including keyway broach set that are designed for longevity and accuracy.

Using a Keyway Broach Set: A Step-by-Step Guide

Preparation

Select the Appropriate Broach and Bushing: Choose the broach and bushing corresponding to the desired keyway size and bore diameter.
Prepare the Workpiece: Ensure the workpiece is securely held in a vise or fixture. The bore should be clean and free of burrs.
Lubricate the Broach: Apply cutting oil to the broach to reduce friction and heat.

Broaching Process

Insert the Broach: Place the broach into the bore, ensuring it is properly aligned with the bushing.
Apply Pressure: Using an arbor press or similar equipment, apply steady, even pressure to push the broach through the workpiece. Avoid applying excessive force, which can damage the broach or workpiece.
Repeat with Subsequent Broaches: After the first pass, remove the broach and insert the next broach in the set. Repeat the process until the keyway reaches the desired depth.
Clean the Keyway: After broaching, remove any chips or debris from the keyway.

Tips for Successful Broaching

Use Cutting Oil: Proper lubrication is crucial for extending broach life and achieving accurate cuts.
Apply Even Pressure: Avoid jerky or uneven pressure, which can cause the broach to bind or break.
Take Multiple Passes: Do not try to remove too much material in a single pass. Multiple passes with progressively larger broaches will produce a cleaner, more accurate keyway.
Inspect the Broach Regularly: Check the broach for wear or damage. Replace worn or damaged broaches to prevent poor cuts.

Maintenance and Care of Keyway Broaches

Cleaning and Storage

Proper maintenance is essential for extending the life of your keyway broach set:

Clean After Each Use: Remove chips and debris from the broach and bushing after each use.
Apply Rust Preventative: Coat the broach with a rust preventative oil to protect it from corrosion.
Store in a Protective Case: Store the broach set in a case or container to prevent damage.

Sharpening Keyway Broaches

Dull broaches can produce poor cuts and are more likely to break. If your broach becomes dull, it may need to be sharpened. Sharpening broaches requires specialized equipment and expertise. Consider sending your broaches to a professional sharpening service or consult the manufacturer's recommendations.

Troubleshooting Common Broaching Problems

Broach Binding

Problem: The broach becomes stuck in the workpiece.

Possible Causes: Insufficient lubrication, excessive cutting depth, incorrect bushing size.

Solutions: Apply more cutting oil, reduce the cutting depth, check the bushing size.

Poor Surface Finish

Problem: The keyway surface is rough or uneven.

Possible Causes: Dull broach, insufficient lubrication, excessive cutting speed.

Solutions: Sharpen or replace the broach, apply more cutting oil, reduce the cutting speed.

Broach Breakage

Problem: The broach breaks during use.

Possible Causes: Excessive force, improper alignment, material hardness.

Solutions: Reduce the applied force, ensure proper alignment, use a broach designed for the material.

Keyway Broach Set: A Summary

Investing in a quality keyway broach set is essential for any machinist or metalworker who needs to create precise keyways. By understanding the different types of broaches, selecting the right set for your needs, and following proper broaching techniques, you can achieve accurate and reliable results. With proper maintenance and care, your keyway broach set will provide years of dependable service. For high-quality keyway broach set, consider Wayleading Tools. Visit our website for a selection of durable and precision-engineered broaches.