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Keyway Broaching

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The keyway broaching method is usually used to cut into small metal parts in large volumes and measured in millimeters. While keyholes for locks are shaped from keyway broaching, the process is mostly done to produce pulleys, gears, small wheels, gun components and tools like wrenches, fasteners and bushings. Read More…

Keyway Broaching Keyway broaching is a high precision, cost effective method of cutting out a keyhole shape in a variety of metal industrial products. The broaching process is done by a keyseater, which is automated machinery used to cut out the specific keyhole shape in metal. Keyways are the most common shape that broaching machines cut out of metal, usually by using an arbor press.
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Leading Manufacturers

Warren, MI  |  586-758-2626

Apex Broaching Systems is a worldwide supplier of standard broaching machines, special purpose broaching machines, fixturing, automation, and cutting tools. We have over 69 years of innovative engineering, skilled craftmanship, quality manufacturing, assembly, and customer satisfaction.

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Apex Broaching Systems $$$

Ypsilanti, MI  |  734-961-0300

American Broach and Machine Company has been a leader in the broaching industry since were founded in 1919, supplying quality products to innumerable customers. We have always offered superior services, like internal broaching, at competitive prices.

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American Broach & Machine Company $$$

Willoughby, OH  |  440-946-1040

For decades Ohio Broach has put back the cutting edge on dulled, unproductive broaches of every size and shape — keyways, splines, squares, hexagons, rounds, serrations and special forms — for companies worldwide

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Ohio Broach & Machine Company $$$

Minneapolis, MN  |  612-729-8301

With 50 years of broaching experience, we have become specialized in manufacturing and engineering of broaches in many shapes and sizes. Our production machining department has complete machining skills.

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Doppler Gear Company $$$

Racine, WI  |  262-639-2272

Production broaching is among the many metal working services we provide. We are a company with longevity and high quality. We are ISO 9001:2000 certified.

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Wiscon Products, Inc. $$$
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Keyseaters also make blind spots, which are slots that don't extend all the way though the whole work-piece, as well as other straight-sided features. The keyhole shape is round with a square cut out at the top. Like all broaching, keyway broaching generates a large amount of excess metal material, which can usually be re-used to form new metal products.

Keyway Broaching Keyway Broaching - Avon Broach and Production Company

The broaching process is usually done in the same facility that fabricates the product and is used as a post-forming process. If a company does not want to invest the money in keyseater machines, or any other broaching machines, they can always go to a broaching shop to get their products produced in a cost-effective and stress-free manner.

Keyway broached products are generally smaller in size, but there is virtually no limit to the dimensions of the part or product being worked on.

All keyway broaching machines are CNC operated electromechanical machines that are composed of a long, skinny tool that has a series of progressively larger sharp teeth that cut through metal and a ram. The tool, called a broach, moves linearly and uses the series of teeth that are arranged to cut the metal in a specific shape.

Keyway broaching can be done to metals with hardness less than Rockwell 35, but very soft metals like brass, copper and aluminum run into problems as well, including depth drift and a poor finish. The process requires a large amount of lubrication, which is provided by water, oil, a water soluble coolant or tap cutting fluid. In order to cut a keyhole shape, the machinery requires support from a broach horn, which is a fixture that supports the broach in a shared circular hole.

In order to effectively cut a keyhole shape, the keyseater must have a rigid set up, as well as proper alignment of the broach tool, work-piece and ram. The process involves turning the broach so the teeth face the back of the press, let the bushing protrude above the work-piece for support alignment, and centering the broach under the ram at the beginning of the cut.

Keyhole broaching machines also have a guiding system above the work-piece to minimize deflection and increase the cutting tolerances.

Keyway Broaching Informational Video